Serie TG Geral Anterior PDF

Service Training
LF-02a
TG Series - General
Name:___________________________________
May 2008
Florian Hinterscheid
This document is intended solely for use in training and is not covered by the ongoing Amendment
Service.
2009 MAN Nutzfahrzeuge Aktiengesellschaft

Reprinting, reproduction, dissemination, editing, translation, microfilming and storage and/or
processing in electronic systems, including databases and online services, is prohibited without
the written consent of MAN.
Table of contents
Contents
Chapter
Introduction
Documentation
Frame / Running gear
Drivetrain
Cab operation
Programme for TG Series - General

1. Structure of maintenance and service literature
2. Designations of different vehicle components and their installation locations
3. CAN bus structure and control unit overview
4. Operating instructions for the different vehicle components
5. Functional sequences and interaction of vehicle components
Module Topic
Duration
Introduction and presentation of TG series
3.0 hours
Structure and presentation of service and maintenance literature,
5.5 hours
including online versions

3
Frame design, including cab suspension, springs, axles, brakes,
8.0 hours
trailer equipment
4
Engine range for TG series with fuel systems, EGR
4.5 hours
Clutch
2.0 hours
Gearshift variants (Kongsberg and cable pull)
Gearbox variants according to model series
2.5 hours
Operation of TG vehicles
2.5 hours
Group work
6.0 hours
10
Discussion of practical work / Farewell / Online assessment
1.25 hours
Total time:
0.75 hours
36,00 Hrs.
Development history of the TG series
TG series
Series overview
TGL
TGA / TGS / TGX
Vehicle identification
Vehicle identification number VIN
Vehicle number
LF-02a[1]. TG-allg.-01-Einfhrung-0805 FH-en.doc
1.1
1.2
Development history of the TG series
1840
1850
1900
1950
2008
1.3
TG series
Series overview
TGL
The TGL was presented in 2005. With gross weight ratings from 7.5 to 12 t, the
MAN TGL covers the whole range of transport tasks in its application field. The 7.5
t version is a super-light specialist vehicle with high payload intended primarily for
use by rental companies, fleets and small companies. The four-cylinder engine
with a maximum output of 240 hp and the light C cab are designed to meet the
corresponding requirements. 4 fixed wheelbase/overhang combinations are
available in this weight class. The complete wheelbase range and the flexible
frame rear end are available from a GWR of 8.0 t to permit realisation of all vehicle
variants. A crew cab complements the range of cabs for local and long-distance
operation. The engine type D08 is used in the TGL.
1.4
TGM
The TGM is in a class of its own with engines of the type D08, offering outputs
from 240 hp to 326 hp and weight ratings of between 13 and 26 t. Combined with
matching chassis variants, this model range has offered economical and reliable
transport solutions since 2005. The crew cab rounds off the range of cabs for local
and long-distance operation. The vehicle components are based on the
Trucknology modular system.
1.5
TGA / TGS / TGX
The TGA covers the weight class from 18 tonnes. The MAN TGS / TGX was
presented in autumn 2007 and was chosen as "Truck of the Year 2008" at the
European Road Transport Show 2007 in Amsterdam.
TGA:
TGS
1.6
TGX
Vehicle identification
Vehicle identification number VIN
MAN Nutzfahrzeuge Aktiengesellschaft
Service Bulletin
Organisation
Date
Publisher
27.07.1999
VSTT
SI Number
442SM
Vehicle Identification No.
vehicle Since 1st July 1999, vehicles have been delivered with a
Modified
modified vehicle identification number.
identification number
The vehicle identification number now has the following format:

Characters 1
Characters 4
to 3
to 6
Example:
Characters 7
to 8 Filler
character "Z"
0 5 Z
Character 9
Check
Character
Character
Characters
10
11
12 to 17
0 0 1 0 2 8
Difference compared with previous vehicle identification number (up to

1999):
The 7-digit vehicle number (formerly "planning number") is no longer part of the
vehicle identification number. Instead, the vehicle identification number has two
"Z" characters as filler characters, a check character and a letter or digit specifying
the model year at the corresponding positions.
1.7
Characters 1 to 3
World Manufacturer Identifier (WMI)

The World Manufacturer Identifier identifies the company that
independently plans, builds and sells the vehicle; also refer to
the overview on Pages 1.9 and 2 in the original SI.
Characters 4 to 6
Type code number
Characters 7 and 8
Filler characters "ZZ" (no significance)
Character 9
Check character introduced as from 01.10.2003:

The check character allows recognition of any mistakes in
transcription of the vehicle identification number and is of no
relevance for the service organisation.
Character 10
Model year, see overview on Page 1.10
Character 11
Plant code (assembly line), see overview on Page 1.10
Characters 12 to 17 Sequential number, line-dependent:

The sequential number is assigned independently of vehicle
type to all vehicles built on a line. The number is assigned in the
order in which the vehicles leave the line. It must therefore
always be considered in conjunction with the plant code.
1.8
Vehicle number
The vehicle number (formerly "planning number") consists of the type code
number and a 4-digit sequential number. The sequential number can also contain
letters.
It is assigned type-independently when construction of a vehicle is defined,
irrespective of the assembly line on which it is then built.
This "planning number" was previously part of the vehicle identification number.
Since 1st July 1999, the vehicle number can no longer be determined from the
vehicle identification number. It is now located on a yellow sticker on the vehicle
frame, for example, and on the identification plate (type plate).
The vehicle number can be found on the identification plate (e.g. type plate on the door pillar on
the passenger's side).
1.9
World
Manufacturer
Identifier:
Model year code:
Plant code:
1.10
WMA
MAN Nutzfahrzeuge AG
VA0 (zero)
MAN Sonderfahrzeuge AG, Vienna, Austria
VAN
MAN Steyr AG, Steyr, Austria
NMA
MAN Trkiye A.S., Ankara, Turkey
SUS
MAN Trucks & Buses sp. z o. o., Starachowice, Poland
SAF
MAN ERF UK Ltd., Swindon, Great Britain
WAG
Neoplan Bus GmbH, Stuttgart, Germany
WVM
Former working partnership MAN-VW (G-series)
01.07.1999 to 30.06.2000
01.07.2000 to 30.06.2001
01.07.2001 to 30.06.2002
3 to 9
analogous to 1 and 2 for model years 2003 to 2009
01.07.2009 to 30.06.2010
01.07.2010 to 30.06.2011 etc.
Salzgitter, Germany (Bus)
Starachowize, Poland (Truck, Bus)
Salzgitter, Germany (Truck)
Munich, Germany (Truck)
Vienna-Liesing, Austria (Truck, Bus)
Munich, Germany (Truck)
Tarnowo Podgorne, Poland (Bus)
Ankara, Turkey (Bus)
Salzgitter, Germany (Truck)
Steyr, Austria (Truck)
Stuttgart, Germany (Neoplan, Bus)
Pilsting, Germany (Neoplan, Bus)
Plauen, Germany (Neoplan, Bus)
Ehrenhain, Germany (Neoplan, Bus)
Documentation
Applications of MAN contractual partners
Access to the intranet
Target group information for sales staff
Repair and maintenance manuals
Basic workshop equipment
Service Information Bulletins
Type code
15
Basic vehicle data
16
Information portal EZIS
19
EZIS via intranet
20
Definition of the most important abbreviations
22
LF-02a[1]. TG-allg.-02-Dokumentation-0805 FH-en.doc
2.1
2.2
Documentation
Applications of MAN contractual partners
Since MAN contractual partners do not have access to the MAN intranet, a
separate access has been set up to the most important information required for
service work and customer support:
This extranet portal allows users to access the same pages as via the intranet.
The contractual partners can choose different applications.

Access to EZIS requires a separate application.
2.3
Access to the intranet

Start Internet Explorer browser.
1.
Enter http://mmhyp.mn.man.de/ in the address line.
2.
The start page of the MAN Nutzfahrzeuge intranet portal is now displayed.
3.
Click the hyperlink * Zielgruppen - Infos (Target group information)

Vertriebs weltweit (Sales worldwide).
Sales worldwide
* Hyperlinks are links which allow the user to click from one document to another
without knowing the address of the document.
These links allow the user to "click" into a file or a document.
2.4
Target group information for sales staff
Selection area for Service - After Sales
Service Literature
Service Information
Service Training Center
MAN Cats
Service Desk
Repair and maintenance manuals
Click
Service Literature
hyperlink.
2.5
Click hyperlink Reparaturanleitungen.
Repair manual
Dear user,
This complete directory of Service Literature contains the spare part numbers,
available languages and date of publication. Please refer to the current price
information of the spare parts organisation for pricing. Please order all publications
exclusively through your service workshops or contractual partners.
The service literature is not subject to an automatic distribution service. A

list of newly published service literature (updated on a daily basis) can be found in
the section "Neuerscheinungen" ("New service literature").
Refer to the PDF files for detailed information.
2.6
An overview of the available service literature and other information portals is

displayed in the navigation window as shown below.
Unit / System
Letter symbol
Engine
Clutch
Manual gearbox - splitter unit, Eaton, Fuller, ZF
Transfer case
Driven, non-steered axle (rear axle), twin-tyred dummy axle
Driven, steered axle (front axle)
Nocn-driven axle (front, leading, trailing axle)
Circuit diagrams, electrical system
Hydraulic steering (steering aids)
Electrical components
Brake systems, air suspension
Axle location, suspension
System description
Cab
Chassis / Frame
Removing/installing major components
Seats
Recommendations on towing, diesel particulate filter, Beka central lubrication
Heating, air-conditioners
2.7
Basic workshop equipment

The screen show below also includes the hyperlink "Empfohlene Grundausstattung einer Werkstatt" ("Recommended basic workshop equipment").
It is possible to choose between the following "Vorrichtungen und Werkzeuge"
("Fixtures and tools"): "electrical", "hydro-pneumatic" and "mechanical".
If this hyperlink is selected and opened, a list is displayed showing workshop

equipment items which are indispensable for service at a modern and efficient
MAN workshop.
Display of the above-described link: "Fixtures and tools (electrical)"
2.8

Under this link you can find all the latest information about our systems and subsystems. This includes all newly published measurement sheets and forms, as
well as a general overview of manufacturer changes or notifications relating to
individual products.
Click
Service
Information
hyperlink.
It is currently possible to choose between twenty-six languages in the screen

shown below.
Select the desired user language by clicking the corresponding button with
the mouse.
2.9
Further options are available in the following screen.

The hyperlinks shown on the right can be clicked and lead to the corresponding
information, bulletins, checklists and official texts shown on the left.

Service Bulletins
Data collections
Forms
Measurement sheets
Checklists
Exemplary Fluke diagrams
2.10
General overview
New service
Service Information for industrial

and marine engines
General overview
29 StVZO (German Road Traffic

Regulations) and official texts
General overview
Supplier codes
General overview
Service Information Bulletins (SIs) are produced and classified based on vehicle
assemblies.
Group
Topic/Systems
Sub-systems
Engine
Electrical system, instruments
Gearbox, axles
Clutch, propshafts and mounts/bearings
Chassis
Steering, pedal mechanism excluding

brake, vehicle lubrication, air suspension
Brakes
Wheel-side brake components, actuation
Body
10
General, technical publications
11
Service products
12
Maintenance, vehicle handling, special

tools
13
Accident prevention, road safety, 29 /

safety inspection
Current
topics
Service
Bulletins
Current SIs for the workshops

Tables and value collections
Fluke
Exemplary Fluke diagrams
Forms
Forms for applications, checklists,

goodwill
Neoplan
Checklists
Unit and type identification, legal issues,

warranty
Current topics
Data
collections
Measurement sheets
Fuel, intake, exhaust, cooling systems. Air

compressor
Tightening torques, fault codes, etc.
Special test and measurement sheets

Neoplan
Checklists for maintenance
Vehicles before TG
Product
Preview of developments
development
Service Information Bulletins can be called up via the Intranet / Extranet. VNSTT
produced the Service Bulletin SM 700 b on this. In June 1998, the Service
Information numbering system was changed from a date-like numbering system
with a suffixed group number (e.g. 170698/10) to sequence numbers with
suffixed group number. (e.g. 23210)
2.11
Note: All Service Information Bulletins, data collections, measurement sheets,

checklists etc. can be viewed in their entirety on the screen and printed out if
required.
Example 1
1. Group 2
Electrical system
2. All Service Information Bulletins are listed.

3. The respective SI number ( highlighted in blue ) can be opened by clicking on
it with the mouse.
Example 2
1. Group 3
Gearbox, axles
2. All Service Information Bulletins are listed.

The respective SI number ( highlighted in blue ) can be opened by clicking on it
with the mouse.
2.12
Service Information search with the search function

The Service Information window also contains an easy-to-use search function.
This function allows input of a search term so that all SIs containing this term can
be found very quickly.
Search function
The search window now opens. The
Search term
can be entered here.
Search
Start and confirm search with the Search button.
2.13
After input of the search term, a list opens showing all the SIs that contain this
search term.
Engines D2066LF21,
D2066LF22, D20, and
D26 Euro 5
The desired Service Information can then be selected by clicking with the left
mouse button.
2.14
Type code
Information about MAN type codes is available in the sections MAN Home
Vertrieb weltweit.Vertrieb weltweit (Worldwide sales).
Type codes
All MAN type codes are listed in these data sheets (screenshot below)
2.15
Basic vehicle data

The headings MAN Home Vertrieb weltweit Fahrzeuggrunddaten (Basic
vehicle data) also contain a search function.
Basic vehicle data

Search and display function
for assembly diagrams for
the respective vehicle or
vehicle type
Click VZ Fahrzeugdaten (VZ vehicle data) ( Suche (Search) ) with the left
mouse button.
2.16
Another window opens after you have clicked the "Search" option with the left
mouse button.
1.
Here you can enter different chassis numbers in the mask provided.
2.
The check box for M360 must be checked in all cases.
3.
You can then start the search by left-clicking "Suche Starten" ("Start search").
2.17
If the search is successful, the corresponding results are displayed.

The assembly order can be displayed by clicking the button "M360 anzeigen"
("Display M360") (delivery status).
In the following window you can copy the corresponding MAN spare part numbers
or search for the drawing in the Electronic Drawing Information System (EZIS)
by means of the respective drawing numbers.
2.18
Information portal EZIS
MAN offers a library of technical drawings in the intranet in "EZIS"

(Electronic Drawing Information System).
EZIS can also be found on MAN Cats II (if it was ordered). The program is
subject to a charge.
The procedure for displaying drawings is described below.
EZIS drawings and documents
Using EZIS
(Electronic Drawing Information System)
it is possible to view or print out drawings and circuit diagrams on a PC.
There are two ways of displaying drawings.
1. The first option is logging in via the intranet. Access authorisation is required to
use EZIS.
2. The second option is via MAN-Cats II. No access authorisation is needed
here as MAN-Cats II logs in automatically!
2.19
EZIS via intranet

Click hyperlink EZIS.
EZIS
Technical documents
After pressing the button "Login", an input window opens in which it is necessary
to enter a user name and password.
User name
Password
2.20
Then confirm with OK.
To search for drawings, click the button "Zeichnungen" ("Drawings"). An input

window is then displayed in which the drawing number of the required drawing
must be entered.
The number of the desired drawing can now be entered. It is possible to enter the
drawing number copied from the host / IMS or MAN basic vehicle data directly by
clicking with the right mouse button.
81.99......
Reset
Perform search
2.21
When the following screen appears, open the desired drawing by clicking with the
mouse in the column "View".
Link to document display
The drawing is displayed on the screen with the installed graphic program.
Definition of the most important abbreviations
PET:
Start of production (PET) of the change number (Added)
PAT:
End of production (PAT) of the change number (Removed)
2.22

Frame design
3
3
Frames for the TGL series
Frames for the TGM series
Frames for the TGA / S / X series
K cross member
Front end
Rear end cross member
Coupling equipment
Special frame cases
10
Cab suspension
12
Suspension
16
Leaf-spring suspension
16
Air suspension:
18
LDS Air Spring Damping System
19
Rear axle X-arm
20
ECAS air suspension system
21
ECAS functions
21
Axles
23
Overview of axle type designations
23
Front axles
23
Rear axles
24
Leading and trailing axles
24
Axle overview according to series
25
27
MAN HydroDrive
Steering knuckle
29
HUB UNIT
29
Steering gear
30
Adjustment with skew steering wheel
31
LF-02a[1]. TG-allg.-03-Rahmen-Fahrwek-0805 FH-en.doc
3.1
Brake systems
Examples
32
System description
38
Special features
39
Disc brake Knorr SN 5
40
Sectional view SN 5
40
Disc brakes Knorr SN 6 and SN 7

Sectional view SN 6 / SN 7
Functional description
41
42
43
Brake clamping
43
Brake release
43
Brake adjustment
44
Disc brake LUCAS-D-Elsa
3.2
32
45

Frame design
Frames for the TGL series
7.5 t
220 x 70 x 4.0 mm up to wheelbase 4200 mm

220 x 70 x 4.5 mm as from wheelbase 4200 mm
8t
220 x 70 x 4.5 mm
Chassis with tubular cross members based on modular principle with multiple
use of parts and subassemblies
Material: S 420 MC (acc. to DIN EN149/2, L2000 QSTE 260/340)
Inside frame width front/rear 950/850 mm
Frames for the TGM series
10/12 t
220 x 70 x 6.0 mm
15 t
220 x 70 x 7.0 mm
18 t
270 x 70 x 7.0 mm
Chassis with tubular cross members based on modular principle with multiple
use of parts and subassemblies
Material: S 420 MC (acc. to DIN EN149/2, L2000 QSTE 260/340)
Inside frame width front/rear 950/850 mm
3.3
Frames for the TGA / S / X series

Rolled
longitudinal
member, TM500
Tubular cross
Hole spacing
same for all
variants
Frame
Open front end
Rolled longitudinal members made of
Higher flexural strength, low frame
high-strength steel QSTE 500 TM,
height
270 mm throughout
Frame reinforcements
Reinforcements between the cross

members and in the middle section
of long wheelbases
Tubular cross members
make the frame torsionally rigid and

ensure minimum load transfer to
body
Spaced holes in the front
Simple assembly of the different axle
section
guides
Single-piece
rear
end
member,
folded
Open front end
Installation of large-area radiators

possible
3.4
K cross member
K cross member in the waisted section for increased rigidity. This component
provides transverse reinforcement in the middle section and also carries valves and
various other components.
K cross
member
Front end
The open front end permits installation of large-area radiators
3.5
Front end with underride guard
Maximum crash safety for

car passengers thanks to
underride guard
Deformation element to
Thread for
absorb energy
towing lug
The front underride guard with crash elements and integrated step offers the
maximum possible safety for car passengers and already meets future safety
standards. The integrated step provides a secure footing for safer access.
3.6
Rear end cross member
The single-piece, folded rear

end cross member is mounted
flush with the longitudinal
members on the semitrailer
frame.
The externally located auxiliary
semitrailer frame provides
reinforcement in the rear section
as well as a wide mounting base
for the fifth wheel, while at the
same time ensuring the lowest
The height-adjustable rear

underride guard permits simple
adjustment of the underride
guard to accommodate different
bodies
3.7
Coupling equipment
Tractor-trailer combination
TGL
Ringfeder 2040G145A
Ringfeder 2040G145B
Tow coupling Ringfeder 6441
Ball head coupling Oris D 85 A

Ball head trailer coupling ORIS D125
max. 3500 kg, only in conjunction with the
rear end cross member (236AD)
TGM
Ringfeder 2040G145A
Ringfeder 2040G145B
Tow coupling Ringfeder 6441
TGA
Ringfeder 4040G150
Ringfeder 5050AW
Rockinger 400G150A
Rockinger 500G6
CAUTION Danger of accidents!

When the trailer coupling is fully locked, the pilot pin 3 must be flush with the
coupling body. A serious accident may result if the trailer coupling is not fully locked.
For this reason, always:
Check whether the pilot pin 3 is projecting at the coupling housing
3.8
Semitrailer TGA / S / X
Jost:
JSK 3-2 5
JSK 37 ME140 15
JSK 37 20
JSK 38-2" 28
JSK 38-3 1/2" 36
JSK 50 50
JSK 42
JSK 36 D
JSK 42 MK26 18
+GF+ (Georg Fischer) SKS 36.20HG2
3.9
Special frame cases
05X -03S Semitrailer TGX -TGS

Tractor unit TS (Tank-Silo)
Weight-optimised tractor unit especially designed for weight-critical applications

such as tank and silo transport operation.
The modified frame in particular provides a weight saving (approx. 360 kg) for this
tractor unit.
3.10
Equipment on the frame for tractor units available ex-works
Ladder behind cab
Walk-on platform up to fifth wheel

Storage box on left
3.11
Cab suspension
The cab suspension at the front consists of a rocker element with maintenance-free
friction bearings and bearing blocks. The rocker guide permits an increase in the
cab tilting angle of 10 compared with the F2000 to more than 65.
Caution: Danger of accident!!!

Always tilt the cab to its end position.
approx.
3.12
The comfort cab suspension is standard for the long-distance cabs L32/ 37/ 40/ 41.
The air-sprung 4-point cab suspension allows a maximum spring travel of +/-45mm.
The air suspension is controlled by means of 3 level-control valves located at the
front right and left and rear right.
Level-control
valve
mechanical
external
Current cab air suspension system

A 4-point suspension is also installed, but the spring bags are no longer controlled
by means of level-control valves. Instead, the control is integrated in 3 spring bags
and is realised by means of a lever on a cam track.
New cab air suspension system

Sliding guide for
valve control
The air spring bag can become
trapped between the level control
mechanism and rolling piston if it
is loaded when not pressurised!
For this reason, connect the air
supply before loading the air
spring.
3.13
Spring extended, venting

position, valve to output open
Lever for valve opening at right

limit position, valve open
Spring always presses level control

mechanism against the upper end stop
of the air spring
Ride level, no filling/venting

possible, valve closed
Lever for valve opening in

middle position, valve
closed
Spring compressed, filling

position, valve to input open
Lever for valve opening at

left limit position, valve
open
3.14
It is not possible to fill the air spring if the air spring bag is trapped between the level
control mechanism and rolling piston.
Cause: Air spring loading with cab weight in unpressurised condition.
Remedy: After installing the air spring, connect the air supply and slowly lower the
cab with a crane.
3.15
Suspension
TGL
Type
Front spring
Rear spring
or
7.5 t
1-leaf parabolic
1-leaf parabolic
2-bag air
8t
2-leaf parabolic
1+1-leaf parabolic
2-bag air
10 t
2-leaf parabolic
2+1-leaf parabolic
2-bag air
12 t
2-leaf parabolic
2+1-leaf parabolic
2-bag air
View of single-leaf spring TGL
TGM
Type
Front spring
Rear spring
or
15 t
4x2 2-leaf parabolic
2-leaf parabolic
4-bag air
18 t
1+1-leaf parabolic
4-bag air
4-bag air
3.16
13 t
4-bag air
18 t
2+1-leaf parabolic
26 t
3-leaf parabolic
TGA / S / X
Front axle:
Parabolic spring
2-leaf (7.5 t)
or 3-leaf
(8.0 t)
(9.0 t)
(9.5 t)
Rear axle:
Parabolic spring
2+1-leaf
(11.5 t)
or 2+1-leaf
(13.0 t)
Trapezoidal spring (6x4)
(26.0 t)
Spring types
Wide-gap parabolic spring
Heavy-duty trapezoidal spring
3.17
Air suspension:
TGL
On TGL vehicles, an air suspension

system can be installed only on the rear
axle.
TGM
Type
Front spring
Rear spring
or
15 t
2-leaf parabolic
4-bag air
18 t
1+1-leaf parabolic
4-bag air
4-bag air
13 t
4-bag air
TGA / S / X
Air suspension
2-bag
(- 8.5 t)
Air suspension
4-bag
(- 11.5 t)
(- 13.0 t)
3.18
LDS Air Spring Damping System
The air spring and shock absorber are combined in one unit (air spring damping
system, LDS).
The air suspension allows the fully loaded forward-control vehicle to be lowered by
90 mm from ride level and to be raised by 90 mm (the total travel is 280 mm).
On a fully loaded low truck - car transporter, the system permits lowering by 60 mm
from ride level and lifting by 160 mm (the total travel is 220 mm).
3.19
Rear axle X-arm

The X-arm performs all axle guidance tasks (transverse and longitudinal) and also
the function of the stabilisers. This means that it is possible to omit trailing arms and
A-arms as well as the stabilisers, thereby achieving a weight saving of approx. 45
kg. The X-arm provides extremely precise axle guidance and therefore improves
tracking, driving stability and roll stabilisation. The favourable restoring force
characteristic improves driving stability in the event of rolling movements.
3.20
ECAS air suspension system

The designation ECAS stands for:
Electronically
Controlled
Air
Suspension
ECAS is an electronically controlled air suspension system for motor vehicles.

ECAS functions
ECAS includes the following functions:
Increased driving comfort and protection of the transported goods through a
lower spring rate and low natural frequency.
Constant vehicle height independent of load.
Possibility of level adjustment on one side.
The following improvements were realised, among others:
Reduced air consumption while driving.
Lower installation volume of complex systems.
Additional functions such as kneeling, overload protection for low-speed traction
control.
Accelerated air filling and venting operations thanks to large valve cross-sections.
The control electronics is the heart of the system.
Task of the control unit
Permanent monitoring of incoming signals
Comparison of these values (actual values) with stored values (setpoints)
Calculation of required control reaction for every deviation
Activation of the solenoid valves
Additional tasks of the control unit
Management and storage of the different setpoints.
Data exchange via the T-CAN and MAN-Cats II
Regular monitoring of the functioning of all system parts
Plausibility check of received signals to detect faults
3.21
The switch "Loading and unloading" present on the series F2000 is no longer fitted
on these vehicles. The "Loading and unloading" function is controlled by means of
the remote control.
3.22
Axles
Overview of axle type designations
V9 - 42 L
Steerable
VOK-08
Series
Nominal axle load (t)

Input torque x~100 (Nm)
H9 - 13 120
Series
Series
Driven front axle
H = Planetary rear axle

HY-13 50
Gross train weight (t)
Non-driven front axle with
drop
VO =
Straight front axle
NO =
Rigid trailing axle
NOL =
Steered trailing axle
HY =
HYD-13 70
Hypoid rear axle
Double hypoid rear axle

with drive-through
HP-13 52
VP-09
Input torque x~100 (Nm)

VOK =
Input torque
x~100 (Nm)
VA7 - 07 50
VA =
HY - 11 75
Nominal axle load (kg x~100)
Gross train weight (t)

Front axles
With leaf-spring suspension:
With air suspension:
3.23
Rear axles
With leaf-spring suspension:
With air suspension:
Leading and trailing axles
Leading axle (steered)
Trailing axle (steered)
3.24
Trailing axle (not steered, for twin tyres)
Drop: 40 mm
Axle overview according to series
Overview of TGL axles
Front axle
Rear axle
3.25
Overview of TGM axles

Front axle
Rear axle
Front axle
Rear axle
Overview of TGA / S / X axles
3.26
MAN HydroDrive
Special feature of this system:

If required, the front wheels are additionally driven at the push of a button. Unlike in
the past, when this was achieved by means of a transfer case and propshafts, this
is realised here with two hydraulic wheel hub motors. In contrast to vehicles with
conventional all-wheel drive, trucks equipped with the MAN HydroDrive system are
also ideally suited for primary use in on-road operation.
In normal driving mode, trucks equipped with MAN HydroDrive drive as usual with
rear-wheel drive. However, the transport task may also require the vehicle to be
driven off unpaved roads - possibly on difficult terrain or on a construction site - or it
may have to cope with difficult driving conditions such as snow or ice.
In such situations, the MAN HydroDrive can be activated in the cab, and the
hydrostatic wheel hub motors integrated in the front wheels additionally drive the
front axle.
Activation of the MAN HydroDrive even functions under load and up to a speed of
28 km/h. The significantly higher traction provided by four wheels allows stuck
vehicles to be moved off again.
3.27
High-pressure connection
Leak
oil
wheel
Leak
oil
wheel
hub
High-pressure connection
Throttle ring
Wheel bearing
The wheel bearings are lubricated with the oil of the HydroDrive. A throttle ring is
fitted so that the pressure on the rear seal does not become too high.
3.28
Steering knuckle
The kingpins have three steps and are inserted from "above" with the axle in
installation position. The grease DEA Acron OS3
( 09.15006.0015 ) is used for initial grease lubrication on assembly. Any grease
nipples still present are needed only for production (initial assembly grease filling)
and are covered by cap closures.
The disc brakes, wheel bearings and axle knuckles are identical for steered front,
leading and trailing axles.
HUB UNIT
The wheel bearing was also changed with the introduction of "LUCAS D-ELSA"
disc brakes. These axles are equipped with "HUB UNIT" wheel bearings.
The bearing assembly is provided with for-life lubrication and is encapsulated.
There is no need for a prescribed annual grease change. When the disc brakes are
replaced, the wheel bearing remains on the axle knuckle as a completely closed
unit.
3.29
Steering gear
The steering gear is a hydraulically assisted dual-circuit ball-and-nut steering
system with variable ratio. The height and rake of the steering wheel are adjustable;
the adjusting mechanism is released by compressed air.
Steering gear type: ZF 8098/8099- Servocom
RBL hydraulically assisted steering C- 700 V
The rear axle steering system is a ZF Servocom RAS ec system.
(Rear Axle Steering).
Diagnose
Versorgung 24V
Elektronisches
Steuergert
Fahrzeugtacho
Fehlerlampe
Raddrehzahlsensor
Lenkwinkelsensor
Steuerventile
Lenkwinkelsensor
Stellzylinder
Druckversorgung
The leading or trailing axle is steered hydraulically by means of a hydraulic cylinder.

Angle sensors are fitted on the steering gear and on the leading or trailing axle.
These sensors measure the steering angle and transmit the values to the control
unit and valve block.
The hydraulic pressure is 160 - 170 bar. This is generated by a maintenance-free
vane pump, which is driven by the air compressor via a cross coupling.
3.30
ZF 8099- Servocom
When replacing the steering gear, fill

sleeve with oil ATF MAN 339 Type
D/F.
Adjustment with skew steering wheel
If the steering wheel is skew, the steering is not adjusted by moving the steering
wheel on the steering spindle. The steering must be in neutral position on the
steering gear as shown in Figure 1. Fine adjustment is then performed by means of
the thread on the pushrod to the steering arm on the axle knuckle.
3.31
Brake systems
Example: TGA EBS Knorr 2.2/2.3
Examples
3.32
3.33
Example: TG-X/S EBS Knorr 5

3.34
3.35
Example: TG-L/M EBS Wabco 2

3.36
3.37
System description
E B S
Electronic Brake System
Sub-functions
EPB
ABS
ASR
Electro-Pneumatic
Antilock Braking
Anti Slip
Brake system
System
Regulation
Fast response
No wheel locking
Short braking
Wheels steerable
distances
when braking
Low wear
Traction control
prevents wheel spin
when accelerating
Continuous brake
deactivation
The Electronic Brake System consists of three sub-functions.

The system components are as follows: EBS control unit, service brake module,
pressure regulating modules, trailer control module, rotational speed sensor, brake
pad wear sensor, axle load sensor.
The EBS control unit controls the pressure in the brake cylinders of the brake
system with the pressure regulating modules.
A connected trailer with ABS is controlled via the brake line with the trailer control
module. Trailers with EBS are controlled by the EBS CAN bus via the ABS socket.
The deceleration rates of the tractor and trailer are matched to each other by the
integrated coupling force control system.
3.38
If the EBS is de-energised, has failed or if there are faults in the system, the system
becomes a pure air brake system with two service brake circuits. When the vehicle
is braked, the service brake valve builds up pressure in the brake cylinders on the
front and rear axles. However, the pressure in the brake cylinders is not regulated
and depends only on the brake pedal position.
Special features
EBS Knorr 5 and Wabco 2 do not have an axle load sensor.
The axle loads are detected by way of the slip behaviour.
The trailer control modules do not have any control units.
In the case of Wabco 2, the EBS control unit, service brake module and front
axle module are installed as one unit in the central brake module.
3.39
Disc brake Knorr SN 5

Sectional view SN 5
The pneumatic disc brake SN 5 from Knorr is used for the light-duty series with a
rim size of 17.5".
The SN 5 transfers the brake clamping force by means of one threaded tube. This
is in contrast to the SN 6 or SN 7, which use two threaded tubes to transfer the
clamping forces.
Cover unit
Brake disc
Compression
spring
Thrust piece
with bellows
Threaded tube
Roller bearing
Shaft
Wear sensor
Lever
Roller chain
Chain wheel
Adapter
Adjusting unit
3.40
Disc brakes Knorr SN 6 and SN 7

The pneumatic disc brakes SN 6 / SN 7 from Knorr are used for the heavy-duty
series with a rim size of 22.5".
The pneumatic brakes SN 6 and SN 7 are also based on the principle of the sliding
calliper brake. Brake callipers of this type transfer the clamping forces to the sliding
mechanism via two threaded tubes.
3.41
Sectional view SN 6 / SN 7
Thrust piece
Brake carrier
with bellows
Brake calliper
Cover unit
Brake disc
Wear sensor
Compression spring
Roller chain
Retaining bracket
Roller bearing
Brake calliper
Chain wheel
Guide bushing
Threaded tube
Brass bushing
3.42
Functional description
Brake clamping
When braking takes place, the force of the brake cylinder (combination or
diaphragm brake cylinder) acts on a lever arm.
This lever arm transmits the force to the bridge via the roller bearing.
The clamping force acts on the inner brake pad via the threaded tubes and thrust
pieces.
After the clearance between the brake pad and brake disc has been overcome, the
reaction force is transmitted to the outer brake pad via the brake calliper (sliding
calliper).
The braking torque for the wheel is produced by the brake pad pressure on the
brake disc.
Brake release
When the forces of the brake cylinder are reduced, the compression spring presses
the bridge with threaded tubes and the lever arm back to the initial position.
3.43
Brake adjustment
The brake is equipped with an automatic, wear-free adjusting device that ensures a
constant clearance between the brake pads and the brake disc.
Each brake operation also results in operation of the adjuster, which has a positive
connection with the lever arm.
Key
6
Lever arm
Threaded spindle with thrust

piece
10
Chain
12
Shift fork
13
Inner sleeve
14
Ball ramp
15
Spring
In the event of increased clearances due to brake pad and brake disc wear, the
threaded tubes are preturned by the adjuster by the wear dimension. The total
clearance is 0.6 - 1.1 mm. (total clearance on both sides of the brake disc)
A smaller clearance can lead to overheating problems and increased
wear!
3.44
Disc brake LUCAS-D-Elsa
All-round disc brake with hub unit Type

LUCAS D-Elsa, internally ventilated
used for disc wheels 22.5"
Hub unit
3.45
Drivetrain
Overview of engine variants for the TG series
TGL engines
TGM engines
TGA / S / X
Engine type plate
Fuel injection systems
Overview of EDC MS 6.1

Schematic fuel circuit diagram for EDC MS 6.1
Common Rail
8
10
11
Overview of EDC 7
11
Schematic fuel circuit diagram EDC 7 Common Rail on D20 Euro 3
14
Legal introduction dates of emission standards
15
MAN Euro 3 solution
15
MAN Euro 4 solution
17
MAN Euro 5 solution
19
Two-stage turbocharging
21
Clutch
22
Clutch on the D08 engine for TGL
22
Shifting / splitter operation with clutch pedal and Comfort Shift
24
Description of Kongsberg gearshift
25
TGA - Cable-controlled gearshift
26
Gearbox variants
27
TGL
27
TGM
28
TGA / S / X
28
Design of the ZF gearboxes TipMatic mid / TipMatic
30
Internal design of the ZF gearboxes TipMatic mid / TipMatic
30
Transfer case
31
TGL / TGM
31
TGA / S / X
32
New-generation transfer case G172
33
LF-02a[1]. TG-allg.-04-Antrieb-0805 FH-en.doc
4.1
4.2
Drivetrain
Overview of engine variants for the TG series
TGL engines
The in-line engines of the D08 series underwent significant design modifications
for the MAN vehicle series TGL. The measures included realisation of new power
output classes with higher outputs and torques as well as high torque rise ratings.
Engine type
KW/ hp
Torque
RPM
4-cylinder
D 0834
LFL 40
110 / 150
570
2400
D 0834
LFL 41
132 / 180
700
2400
D 0834
LFL 42
151 / 206
830
2400
4.3
6-cylinder
D 0836
LFL 40
176 / 240
925
2400
TGM engines
The in-line engines of the D08 series from 240 hp with new power output classes,
higher outputs and torques and high torque rise ratings are used for the MAN
vehicle series TGM.
Engine type
KW/ hp
Torque
RPM
6-cylinder
4.4
D 0836
LFL 40
176 / 240
925
2400
D 0836
LFL 41
206 / 280
1100
2400
D 0836
LFL 43
240 / 326
1250
2400
TGA / S / X
D20 engines
EURO 4 with EGR + PM-KAT
D2066 LF14 CR (4-V) 228 kW (310 hp)

1550 Nm
1900 rpm
1000 - 1400 rpm
D2066 LF13 CR (4-V) 257 kW (350 hp)

1750 Nm
1900 rpm
1000 - 1400 rpm
D2066 LF12 CR (4-V) 287 KW (390 hp)

1900 Nm
1900 rpm
1000 - 1400 rpm
D2066 LF11 CR (4-V) 316 KW (430 hp)

2100 Nm
1900 rpm
1000 - 1400 rpm
EURO 5 with SCR
D2066 LF22 CR (4-V) 294 KW (400 hp)

1900 Nm
1900 rpm
1000 - 1400 rpm
D2066 LF21 CR (4-V) 321 KW (437 hp)
SCR mixer
2100 Nm
1900 rpm
1000 - 1400 rpm
D26 engines
EURO 4 with EGR + PM-KAT
D2676 LF01 CR (4-V) 353 kW (480 hp)

2300 Nm
1900 rpm
1050 - 1400 rpm
EURO 5 with SCR
SCR mixer
D2676 LF12 CR (4-V) 353 KW (480 hp)

2300 Nm
1050 - 1400 rpm
D2676 LF11 CR (4-V) 397 KW (540 hp)

2500 Nm
1900 rpm
1900 rpm
1050 - 1400 rpm
4.5
D28 engines
Only for TGA

D2866 LF23 (4-valve + EGR)
228 kW (310 hp) 1800 - 1900 rpm
1500 Nm
900 - 1300 rpm

265 kW (360 hp) 1800 - 1900 rpm
1700 Nm
900 - 1400 rpm

301 kW (410 hp) 1900 rpm
1850 Nm
900 - 1300 rpm

338 kW (460 hp) 1700 - 1900 rpm
2100 Nm
900 - 1300 rpm
D2876 LF12 CR (4-valve + EGR)

353 kW (480 hp) 1900 rpm
2300 Nm
1000 - 1300 rpm
D2876 LF13 CR (4-valve + EGR)

382 kW (530 hp)
1900 rpm
2400 Nm
1000 - 1400 rpm
Only for heavy-duty tractor V10
D2840 LF25 CR (4-valve + EGR) Euro 3

485 kW (660 hp)
2700 Nm
1900 rpm
1000 - 1600 rpm
For V8 heavy-duty tractors and V8 semitrailer tractors
D2868 LF02/03 CR (4-valve + SCR+ AdBlue) Euro 5 with OBD

500 kW (680 hp)
2700 Nm/3000 Nm
4.6
1900 rpm
1200 - 1500 rpm
Engine type plate
MAN - Werk Nrnberg

Typ
D2676 LF 03
Motor-Nr. / Engine-no
N I / N II
N I / N II
Feld
5459170015B2E1
Engine type designation
e.g. D2676 LF 03
Fuel type, diesel
26
+ 100 = bore diameter, e.g. 126 mm
Designates the stroke 6 = 155 mm, 7 = 166 mm
Number of cylinders 6 = 6 cylinders, 0 = 10 cylinders, 2 = 12 cylinders
Type of charging, Turbocharging with charge air cooling
Engine installation position:
03
Truck Forward-control vertical engine
OH
Bus
Rear-installation vertical engine
UH
Bus
Rear-installation horizontal engine
Engine variant; particularly important for spare part supply, technical data
and setting values.
4.7
Fuel injection systems

Overview of EDC MS 6.1
WasserKraftstoffKraftstoff- temperatur
druck
ldruck
temperatur
Motor
Drehzahl 2
Drehzahl 1
Ladelufttemperatur
(Euro3)
Nadelbewegungsfhler
Ladedruck
Motorseitiges
Steuergert
EDC MS6.1
Klemme 30
Klemme 15
Abgas- Rckfhrungsventil
(EURO3)
Datenverbindung
Motor-CAN-Bus
Fahrpedal
Fahrzeugfhrungsrechner
Kupplung
Lenkstockschalter
Motorbremse
Kombiinstrument,
Warnlampe
Instrumenten CAN-Datenbus
Fahrerhaus
Triebstrang CAN-Datenbus
Geschwindigkeit
Bremse
MS61ALG2.CDR
4.8
As with conventional fuel injection systems, the EDC system also consists of an
injection pump and a governor.
A control sleeve pump is installed in the EDC MS 6.1 (M = fuel delivery control; S
= timing adjustment). Both systems are controlled by a microprocessor-based
control unit. The program memory of this control unit contains all the maps defined
for the engine.
The great advantage of the EDC system is the actuator mechanism, which is
always the same irrespective of the map. In other words, the control unit is
exclusively responsible for the maps, corrections, etc. On mechanical governors,
in contrast, all the components that affect the control characteristic (flyweight
parts, spring sets, and compensating devices such as torque control spring
capsules, stops, etc) are actually integrated in the governor. If it is wished to
change the control characteristic, it is therefore necessary to replace these parts.
In the EDC system, there is no mechanical connection between the accelerator
and governor. The accelerator has an integrated pedal travel sensor. The driver
request is sent to the vehicle management computer via a PWM (pulse-widthmodulated) signal.
4.9
Schematic fuel circuit diagram for EDC MS 6.1
4.10
Common Rail
Overview of EDC 7
Fuel pressure
ahead of filter
Rail pressure sensor
Rotational speed sensor
Pedal travel sensor
Water Temperature
Boost pressure sensor

Camshaft sensor
Operating unit
High-pressure pump
Brake
Control unit
CAN
EGR actuator cylinder
FGB/FGRswitch
K line
Terminal 15
Injector
Terminal 30
Clutch
Vehicle
Management
Computer
(FFR)
4.11
The CR fuel injection system consists of a quantity-controlled high-pressure pump

that can produce a very high fuel pressure (max. 1800 bar) in a fuel reservoir, the
"rail". The rail makes this pressure available to the "fuel injector" for finely
atomised injection.
The main characteristic of CR systems is therefore the fact that pressure

generation and fuel injection from the rail are separated. This time-controlled fuel
injection system therefore overcomes the typical restrictions of conventional camcontrolled systems. The increased average fuel injection pressure and injection
timing can be freely selected over a wide range independently of the engine
operating point.
The quantity-controlled high-pressure pump, which is fed by a flanged-on
predelivery pump, delivers as much diesel fuel as required to the rail until the
desired fuel pressure is reached. This pressure accumulator is connected via
hydraulic lines with the fuel injectors. The fuel injectors are controlled by solenoid
valves and inject a quantity of the stored fuel defined by the control unit into the
combustion chambers of the engine.
This allows optimisation of the combustion process.
The hydraulic components of the fuel injection system are monitored by the control
unit. The sensors of the control unit continuously measure data relating to engine
and vehicle operation. For example, the rail pressure sensor, control unit and
quantity-controlled high-pressure pump form a control loop to produce the desired
rail pressure. Other sensors, such as coolant temperature sensor, charge air
temperature sensor or atmospheric pressure sensor, help to optimally adapt the
engine to changing ambient conditions.
4.12
Common rail components
Injector
Rail with
pressure
Control unit
High-pressure pump with gear delivery pump and fuel metering unit (M PROP)
Rail with pressure connections, rail pressure sensor (RDS) and pressure limiting
valve (DBV)
Changed valve setting D2876LF12 / 13 and D2066LF !!!!

Intake 0.5 mm
Discharge
0.8 mm
EVB
0.6 mm
4.13
Schematic fuel circuit diagram EDC 7 Common Rail on D20 Euro 3
KSC (fuel
Injector
Return channel in cylinder head
service centre)
Overflow valve in return line
Rail pressure sensor
Flame
Pressure limiting valve
start
system
High-pressure pump with gear
delivery pump
4.14
Legal introduction dates of emission standards

2003
2004
2005
2006
2007
2008
2009
10/2005
Euro
New types, incl. OBD 1

Durability
In use compliance
10/2006
*)
Euro
New registrations, incl. OBD 1
*)
Durability
In use compliance
10/2008
Euro
New types, incl. OBD 2
OBD = On Board Diagnosis
Euro
**)
10/2009
New registrations, incl. OBD 2

*)
**)
OBD 1: Monitoring of engine with respect to OBD limits (NOx 7 g/kWh, PM 0.1 g/kWh)
Monitoring of exhaust after-treatment for "major functional failure"
**)
OBD 2: Monitoring of engine and exhaust after-treatment with respect to OBD limits
(NOx 7 g/kWh, PM 0.1 g/kWh) i.e. catalytic converter efficiency (NOx or NH3 sensor)
Monitoring of OBD and emission-relevant information by the interface to vehicle control
units
MAN Euro 3 solution
Comparison of systems for emission reduction

internal exhaust retention
Charge air
40 C
High
temperature
of cylinder
charge
additionally:
Required
NOxvalues are
not achieved
Low retention
600 C
Lower fuel
injection rate
Later start of
injection
Worse efficiency
High consumption
Oil contamination
EURO
rate
Exhaust gas
External cooled exhaust gas recirculation

Charge air
40 C
Lower
temperature of
cylinder charge
High recirculation
rate
160 C
No further
Required
NOxvalues
are achieved
measures
are
necessary
Euro 4
High efficiency
Low consumption
Clean oil
EURO 3
potential
Cooled
exhaust gas
4.15
Exhaust gas recirculation (EGR)
Cooled and regulated exhaust gas recirculation systems are installed in engines
from Euro 3. These systems reduce formation of nitrogen oxide.
The exhaust gas mixed with the intake air reduces the oxygen concentration in the
charge gas and increases its temperature. Both these factors reduce the
combustion temperature and formation of nitrogen oxide. This also reduces the
quantity of exhaust gas. If too much exhaust gas is recirculated, soot and carbon
monoxide emissions increase due to the lack of oxygen. The recirculated quantity
of exhaust gas must be restricted so that sufficient oxygen remains for
combustion.
Function:
The exhaust gas is routed to the turbocharger in separate exhaust manifolds
(cylinders 1,2,3 and 4,5,6). The exhaust gas is routed from 2 outlet points (1st
outlet from cylinders 1,2,3 and 2nd outlet from cylinders 4,5,6) in separate pipes
through a heat exchanger connected to the cooling circuit. The cooled exhaust
flow is brought together only after the check valves at the end of the heat
exchanger. This separate exhaust gas routing results in a pulsating exhaust gas
flow, which is required to overcome the charge pressure in the intake manifold.
The quantity of recirculated exhaust gas can be restricted or interrupted (engine
braking mode) by means of the electro-pneumatically controlled shutoff flap. This
is controlled by the EDC control unit. The charge air temperature sensor is located
in the intake manifold. This is used to switch off EGR as required in order to
ensure that the intake air does not become too hot.
ChargeEngine
Air
air
filter
EGR
valve
4.16
Pressure
EGR
peak
cooling
MAN Euro 4 solution
New engine generation

D20 Common Rail + cooled exhaust gas recirculation + MAN PM-KAT
The MAN PM-KAT filter is a continuously operating particulate matter

separating system featuring open channels
Particulate separation is effected by specially triggered turbulence during

the deflection of exhaust gases in the separator and their passage through
the sintered metal fabric.
The dissolution of the particulates retained in the fabric is the result of the
permanent chemical reaction brought about with the aid of the NO2 formed
in the upstream oxidising catalytic converter.
As a result, the MAN PM-KAT is maintenance-free and does not clog up. In
addition, an above-proportional amount of the smallest particulates (< 40
nm) is eliminated.
Engine
Air
Chargeair
filter
Pressure
EGR
valve
EGR cooling
peak valves
PM-
KAT
4.17
Schematic diagram of the PM-KAT
Chemical conversion in the catalytic converter
Pre-oxidation platinum catalytic converter: 2NO
Particulate matter separator: 2NO2+ C CO2+
MAN PM-KAT system in the TGA
PrePM separator
4.18
MAN Euro 5 solution
Catalytic converter + AdBlue (Selective Catalytic Reduction)
In the MAN AdBlue solution, the emission control required for Euro 5 is
performed using injected aqueous urea in a downstream diesel catalytic converter
(SCR catalytic converter)
AdBlue
tank
Urea metering system (HDS)

AdBlue
mixer
O-CAT
AdBlue mixer
R-CAT
Ammonia formation CO
CO(NH2)2+H2O
2NH3 + CO2
R-CAT
NOx reduction
4N
4NO + O2 + 4NH3
4N2 + 6H2O
O-CAT
NH3 oxidation
4NH3 + 3O
2N2 + 6H2O
MAN AdBlue system for Euro 5 in TGA / S / X

Injection
of AdBlue
AdBlue mixer
Reduction catalytic converter

Oxidation catalytic converter
4.19
Installation on engine
Exhaust turbocharger
Exhaust
temperature sensor
Metering valve
AdBlue mixer
4.20
Urea nozzle
Two-stage turbocharging
The principle of two-stage turbocharging allows generation of very high boost

pressures. In the upper rpm range, these pressures would lead to overloading of
the engine (particularly cylinder pressure) as well as of the peripheral devices (e.g.
charge air cooler). For this reason, it is always necessary to limit the boost
pressure. In the simplest case, this is done by a pressure-loaded and springloaded waste gate that limits the boost pressure above a certain fixed value.
The D0834 LFL 42 additionally features a boost pressure control valve controlled
by the electronic engine controller (EDC). This makes it possible to achieve an
optimum boost pressure characteristic.
4.21
Clutch
Clutch on the D08 engine for TGL
Clutch MF-362 for D0834 LFL

Venting
connections
Connection
for travel
sensor
Travel sensor
Travel
sensor
The travel
sensor is
calibrated
with MANCATS
This clutch has only a clutch

The clutch is
pushed upon
operation!
slave cylinder and no booster.
The version shown above is installed for gearboxes 6S850 and S5-42; in the case
of gearbox 6AS850, clutch operation is via a fork with a clutch master cylinder
mounted on the top side.
4.22
Clutch MFZ-395 for D0836 LFL with 6-cylinder engines
Note:
As
from
6-cylinder
engines,
clutch
operation is by pulling!!
With
clutch
gearboxes
and
booster
clutch
for
manual
actuator
for
Clutch booster
Clutch for TipMatic with 6-cylinder engines
A conventional-design dry single-disc clutch is installed. Disengagement is by

pulling. This is performed by an electro-pneumatic or pneumatic clutch actuator
controlled by the gearbox control unit.
The solenoid valves for filling and venting, a travel sensor and the electronic
controller are mounted on the pneumatic actuating cylinder of the clutch actuator.
4.23
Shifting / splitter operation with clutch pedal and Comfort Shift

Shift operations can be performed only with the clutch pedal.
The pushbutton on the shift lever knob is installed for activation of the Comfort
Shift function. The other functions of the gearshift are the same. A mechatronic
module is fitted on the shifting device.
The clutch master cylinder does not have a solenoid valve.
Double master cylinder
Pressure distributor
Old shift lever knob design
Clutch
actuation
for Comfort
Shift
Comfort Shift
Splitter unit
Range unit
New shift lever knob design
Splitter unit switch
ON
OFF
Range unit switch
4.24
Description of Kongsberg gearshift
HGS (Hydraulic GearShift)

The previous mechanical shift linkage has been replaced by a hydraulic gearshift
(HGS) from Messrs. Kongsberg. This hydrostatic gearshift consists of a shift
transmitter below the shift lever, a compensating reservoir, hydraulic connecting
lines (4 control lines: rear gears, front gears, left gate, right gate) to the gearbox
and the gear and gate selection cylinders on the gearbox. Bleeding is possible
with a bleeding device via the bleeder nipple/screw.
! Only use fluid M 3289!

! Caution: Do not use brake fluid
Hose to the compensating reservoir
Hydraulic master cylinder in the cab
Disconnection point
Cab frame
Selection
Hydraulic slave
cylinders
Shifting
4.25
TGA - Cable-controlled gearshift
The cable gearshift consists of a cab-side shift transmitter, two shift cables with
holders and selector levers on the gearbox.
4.26
Gearbox variants
TGL
ZF ECOLITE
S5-42 OD
i = 5.72 - 0.76
5F/1R
67 kg
(150 hp)
6 S 850 OD i = 6.72 - 0.79

6F/1R
111 kg
(180-210 hp)
ZF-ASTronic-LITE (TIPMATIC)
6 AS 850
i = 6.72 - 0.79
6F/1R
(180-210 hp)
EATON
FS 8309 DD i = 12.6 - 1.00
9F/1R
FSO 8309 OD
9F/1R
154 kg
(240-280 hp)
i = 9.4 - 0.75 154 kg

(240-330 hp)
ZF-ASTronic-MID (TIPMATIC)
12 AS 1210 TO
12F/1R
i = 10.33 - 0.81
190 kg
(240-330 hp)
4.27
TGM
EATON
FS 8309 DD i = 12.6 - 1.00
9F/1R
154 kg
(240-280 hp)
FSO 8309 OD
i = 9.4 - 0.75 154 kg
9F/1R
(240-330 hp)
ZF-ASTronic-MID (TIPMATIC)
12 AS 1210 TO
i = 10.33 - 0.81
12F/1R
190 kg
(240-330 hp)
TGA / S / X
ZF ECOSPLIT
16S182 OD
i = 13.80 - 0.84
16F/2R 289 kg
16S192 DD
16S222 OD
16S222 DD
16S252 OD
TGA
310/360/410/460 hp
i = 13.80 - 0.84
16F/2R 319 kg
TGA
310/390/430/460 hp
i = 16.41 - 1.00
16F/2R 319 kg
TGA
310/360/410 hp
i = 13.80 - 0.84
16F/2R 317 kg
4.28
310/350/410 hp
i = 16.41 - 1.00
16F/2R 317 kg
TGA
TGA
480/530 hp
MAN TipMatic (ZF)

12 AS 2140 TD
TGA
12F/2R i = 15.86 - 1.00
310 - 460 hp
12 AS 2301 TO
TGA
12F/2R i = 12.33 - 0.78
350 - 460 hp
250 260 kg
ZF ECOMAT
5 HP 500
i = 3.43 - 0.83
220 hp
5 HP 590
i = 3.43 - 0.83
280 hp
with retarder + EST18
(optional)
5 HP 600
i = 3.43 - 0.83
310/360 hp
with retarder
i = 5.6 - 0.83
310/360 hp
+ EST18
(optional)
279 - 335 kg
ZF TC-TRONIC
WSK 440 + 12 AS 2740 TO
i = 12.33 - 0.78
660 hp
Heavy-duty tractor
4.29
Design of the ZF gearboxes TipMatic mid / TipMatic

(Function diagram) 6-cylinder
The gearbox has a two-countershaft design.

Reaction force
Force
Reaction force
Second countershaft
Countershaft
Main shaft
The reaction forces cancel each other out at the main shaft
bearing
Internal design of the ZF gearboxes TipMatic mid / TipMatic
Splitter unit
Reverse gear
Gearbox
Range unit
brake
Three-speed unit
with reverse gear
Output flange
The gearbox is designed as a range-change gearbox.

4.30
Transfer case
TGL / TGM
MAN transfer case

G102 (0.98/1.6 option)
with connectable front axle drive or with longitudinal offset
On-road gear:
Weight:
0.983
Off-road gear:
1,607
143 kg
10.xxx
TGL
14.xxx/18.xxx
TGM
4.31
TGA / S / X
MAN transfer case

G 172 New, more powerful version, greater axle spacing
G 173 With neutral position for PTO
G 252 / G253 With connectable front axle drive or with longitudinal offset
G 172/G173
On-road gear:
1.007
0.981
Off-road gear:
1.652
1.583
Weight:
360 kg
up to 430 hp
TGA
4.32
G252/G253
394 kg
41.480
TGS
TGX
New-generation transfer case G172

The increased vertical shaft spacing between the drive shaft and output shaft
results in a smaller propshaft deflection angle, reduced noise and a longer service
life of the cardan joints.
The oil filter removes metal abraded matter from the gear oil, and it was
possible to reduce weight by omitting the oil pump.
Oil filter
Oil filter
4.33
Cab operation
The CAN bus structure
Operation at driver's workplace
Cab front panel
Inspection and maintenance locations
Cab tilt mechanism
Cab tilting - hydraulic
Door modules
12
Auxiliary air conditioning system
13
Switch / pushbutton for intelligent brake coupling
15
Switch: FGR (cruise control) / FGB (speed limiter) / ACC switchover
17
TipMatic gearbox operation
18
Emergency functions in the event of failure
19
Manoeuvring position ("DM" and "RM"):
20
Towing and tow-starting
21
Tow-starting AS-Tronic
21
Roller test bed
21
LF-02a[1]. TG-allg.-05-Fahrerhaus-0805 FH-en.doc
5.1
Cab operation
The CAN bus structure
Background:
Many open-loop and closed-loop control operations must nowadays be performed
by electronic control units, since mechanical or electrical control systems do not
offer the required level of performance.
The electronic control units require information to perform all the tasks reliably,
and they receive this from connected sensors as well as from other control units.
To minimise the number of sensors required in the vehicle, the goal is to measure
each measured value (e.g. water temperature, engine) only once, and to then
make this measured value available to all control units.
In the TG series, the control units are connected by means of a data network, the
CAN network (CAN = Controller Area Network, BUS = Binary Unit System).
5.2
CAN = Controller Area

Network:
Drivetrain CAN
CAN Bus = control unit
Engine CAN
networking via data
Instrumentation
Instrument CAN
lines
Instrument CAN
Retarder
Tachograph
Brake control
Central on-board computer
Drivetrain CAN
Vehicle management computer
Engine CAN
Air suspension
Engine control
Transmission control
Air management
5.3
Operation at driver's workplace

TGL without multifunction steering wheel
5.4
TGA and TGL / TGM with multifunction steering wheel
TGS / X
5.5
Cab front panel

Release for front
panel in cab
Press the lever up

When tilting the cab,
always open the front
panel !! (see section on
cab tilt mechanism)
5.6
Inspection and maintenance locations
Compensating reservoir for clutch

and gearshift operation
Filler neck for engine oil
Filler neck for windscreen

washer system
Emergency release
connection for spring-type
Filler neck for coolant - exercise

caution when the engine is hot
5.7
Cab tilt mechanism

The cab tilt mechanism is accessible behind a cover on the right entrance box. An
information plate is fitted on the rear of the cover.
The rocker guide permits a cab tilting angle of 62. An electrohydraulic cab tilt
mechanism is offered as an option.
Information plate for cab tilt mechanism
Move lever 5 up (tilt) or down (lower).

Magnetic pushbutton with cap 4a: press for raising and lowering.
Magnetic pushbutton without cap 4b: Touch with a metal object (e.g. vehicle key)
for raising and lowering.
5.8
Cab tilting - hydraulic
1 Lever of reversing valve

2 Hexagon for fitting the wheel nut wrench
Caution: Always tilt the cab to its

limit position!
5.9
Steering wheel adjustment TG-A , TG-L, TG-M
Press and hold the pushbutton on the driver's seat base with your heel.
Adjust the height of the steering wheel and its distance from your body.
Release the pushbutton again.
5.10
Steering wheel adjustment TG-S, TG-X

The supply pressure in the compressed air system must be at a
sufficient level for adjustment of the steering wheel.
First adjust the driver's seat and then adjust the steering wheel to the
changed
Press rocker switch 1 at top

Adjust the height of the steering wheel and its
distance from your body
Release the rocker switch
The steering wheel is locked again after approx. 5
seconds.
or
Press rocker switch 1 at bottom
The steering wheel is then locked again more quickly.
Switch location:
CAUTION
Danger of accident!
Adjust the steering wheel
only when the vehicle is
stationary and when the
parking brake is applied.
5.11
Door modules
General
The buttons of the door module on the driver's side can be used to electronically
control the window lifters, central locking system, mirror adjustment and mirror
heating.
The door module on the passenger's side controls only the window lifter on the
passenger's side.
The door module on the driver's side and the door module on the passenger's side
communicate with each other via a data bus.
Switch assignment
Mirror heating
Joystick
Mirror
preselection
left / right
Mirror
selection
2. Mirror
position
Main mirror,
passenger's
side
TG A version
Window
lifter
Central locking
TG X / S version
5.12
Auxiliary air conditioning system

The auxiliary air conditioning system is completely integrated in the driving airconditioning system. This means that existing operating elements for control,
delivery, distribution, temperature adjustment and air cleaning can also be used for
operation of the auxiliary system when the vehicle is stationary.
Cold accumulator
Expansion tank
Air-conditioning unit
with heat sink
Evaporator unit
Control and
distribution unit
The combined driving and auxiliary air-conditioning system increases operating

safety and economy in addition to enhancing driver comfort and performance.
The best possible air distribution in the cab is achieved with a low noise level
through utilisation of the optimised air routing of the vehicle air-conditioning system
for the auxiliary system as well. This means that no additional air ducts are
necessary.
5.13
Air conditioning during break and waiting times

When the engine is switched off, cold is supplied by the accumulator, which stores
excess cold while the vehicle is moving. During operation of the auxiliary airconditioning system, the fan and control functions of the vehicle air-conditioning
system remain active; this means that the driver does not need to adjust or change
anything.
Air conditioning while sleeping
Sleeping in the vehicle is no longer a problem even during very warm or sultry
nights thanks to the auxiliary air-conditioning system, which also de-humidifies the
air. In order to ensure that it does not become too cold in the cab as the night
temperatures fall, the control system first reduces the cold supply and then fully
switches off the accumulator if the temperatures fall further. If this is not sufficient
to prevent excessive cooling, the fan is operated only periodically. However, an
adequate supply of fresh air is always guaranteed.
Switch for switching the auxiliary air-conditioning system on and off and for
charging
Pushbutton for operation of the auxiliary air-conditioning system
5.14
Switching on
The air-conditioning system is switched on in driving operation by pressing the AC
switch. When the ignition is switched off, the cab can be air-conditioned by
switching on the auxiliary air-conditioning system with the auxiliary AC switch.
Switch / pushbutton for intelligent brake coupling
Switch:
Function:
It is possible to select two switch states:

Switch off
Retarder operation possible only with the continuous brake momentary switch
Switch on
Retarder operation with the continuous brake momentary switch is possible and
the following automatic functions can be activated in parallel.
Automatic functions:
Activation in brake pedal lead travel

Retarder stages are integrated in the free travel of the brake pedal (approx. 25 %
of the total actuating range). The service brake is not yet active in this range. The
amount of activated retarder torque depends on the vehicle load. It is a maximum
of 50 % of the maximum torque, but without engine brake operation. The retarder
icon is additionally shown on the display.
5.15
Automatic braking function with cruise control operating lever
The automatic braking function is used to inform the FFR of a desired speed. In
conjunction with the FFR and engine CAN, the EDC system regulates the vehicle
speed to the desired speed (as long as the engine power is sufficient for this).
The automatic braking function is activated 4km/h above the set cruise control
speed. The speed threshold of 2 km/h is defined as part of EOL parameterisation
and can be changed by the service organisation. The FFR manages this function
and the braking power of the retarder/intarder or of the engine brake is increased,
depending on the engine load.
Activation by adaptive braking
A further comfort function is provided by the brake pedal.

When the vehicle is braked with the brake pedal, the speed is stored at which the
brake pedal is released (= adaptive braking).
The speed is stored and is maintained as the new speed by the automatic braking
system as long as the required braking torque of the retarder is sufficient.
This function is deactivated when the accelerator is pressed or the cruise control
stalk is operated.
Activation by the accelerator
A further comfort function is available when the accelerator is in normal position.

The current vehicle speed is saved and the vehicle is automatically braked if the
speed exceeds the current speed by 4 km/h.
This function is deactivated again when the accelerator or brake pedal is pressed
or the cruise control stalk is operated.
5.16
Switch: FGR (cruise control) / FGB (speed limiter) / ACC switchover
Function:
The FGR/FGB/ACC (cruise control/speed limiter/ACC) switch is used for switching

from the cruise control function to the speed limiter function. Cruise control (FGR):
The switch FGR/FGB/ACC (button 10) must be set to the FGR function.
It is possible to set a desired speed with the cruise control stalk switch A429. The
cruise control function is also deactivated if the driver presses the brake pedal
(signal from EBS via T-CAN) or clutch pedal (signal from clutch travel sensor
B362).
Speed limiter (FGB)
The switch FGR/FGB/ACC must be switched to the FGB function.

Using the cruise control stalk switch A429, it is possible to set a maximum speed
that cannot be exceeded. An icon appears on the display when the maximum
speed is reached.
The speed limiter function is not switched off but is temporarily interrupted when
the accelerator is pressed hard (e.g. to overtake, like with kick-down).
The speed limiter is activated again when the current vehicle speed falls below the
speed limit.
5.17
TipMatic gearbox operation

Range selector switch A434 -
Cruise control / gearbox switch A429
Pushbutton
Steering column
Display on instrument cluster
The driving direction and starting gear are selected with the DNR switch. "D" for
forward gears, "R" for reverse gears and "N" for neutral.
The current position of the DNR switch is forwarded to the transmission control.
5.18
It is possible to switch to automatic mode with the end pushbutton. In this mode,
the transmission control shifts gears independently. Automatic mode is switched
off again by means of this pushbutton or by manual gear selection. Momentary
operation changes to manual operation and shifts up or down by one gear.
When driving, the reverse gears are blocked when the direction of travel is
forwards, and the forward gears are blocked when reversing.
When the vehicle is stopped, the current gear or the gear selected by the DNR
switch is maintained as the gear for driving off, depending on which is the lower
gear.
Emergency functions in the event of failure

Automatic mode is activated if the cruise control/gearbox switch fails.
If the DNR switch fails, it is possible to shift from forward gears via neutral to
reverse gears and vice versa with the cruise control/gearbox switch.
Autoskip function:
If the engine speed falls below a certain limit (900 rpm) in manual mode, it is
possible to skip several gears by "Downshift" (hold) operation. The gear
recommended by the transmission control is then engaged.
In position "D" , the TipMatic selects the starting gear depending on the current
vehicle load (standard starting gear = D3)!
5.19
Manoeuvring position ("DM" and "RM"):

In Manoeuvring mode, the whole travel of the accelerator is used to close the
clutch; the engine speed is limited to 850 rpm.
The manoeuvring gears "DM" and "RM" are for extremely slow driving, e.g. when
coupling and uncoupling a semitrailer or trailer.
Overview of switch variants:
Switch, 7-stage, for TipMatic 4x2, 6x2,
until May 2004
Buses, rigids also after 2004
Switch, 5-stage, for TipMatic 4x2, 6x2,

from June 2004
In position "D", the TipMatic gearbox automatically selects the starting gear depending on
the vehicle load (standard starting gear = D3)
Switch, 6-stage, for TipMatic 6x4, 8x4, 8x2, 6x2,
4x4, 6x6, refuse collection vehicles
Switch, 6-stage, for TipMatic "Offroad" 4x4, 6x6,

8x6, 8x8
Switch, 6-stage, for TipMatic with torque

converter clutch (WSK) (TC Tronic)
(DM Starting gear under load via the torque
converter clutch)
Switch, 5-stage, for TipMatic Fleet
5.20
Towing and tow-starting

The drivetrain to the drive axles must always be disconnected for towing! This can
be done by removing the propshaft or axle shafts.
Tow-starting AS-Tronic
Tow starting of the engine is not possible!
Roller test bed

After driving into the test bed rollers, the gearbox must be shifted to Neutral,
otherwise the AS-Tronic control unit will detect a moving vehicle and close the
clutch.
The vehicle may then independently drive out of the test bed rollers!
Neutral
D
DM
R1
RM
5.21
Worksheet on sales designations, wheel configurations and

installation plates
What door designation does the training vehicle have?

Weight:
Power output:
What cab type does the vehicle have?
What wheel configuration does the vehicle have?
In what RAL colour is the cab painted?
What values are entered on the installation plate for the tachograph?
L:
W:
K:
When was the tachograph inspection performed?
What K value applies to the vehicle (exhaust-emission check)?
Which item number does MAN prescribe for the air filter insert, and what
characteristic does the air filter insert have?
No.:
Arbeitsblatt 1 LF-02a-en.doc
Characteristic:
1.1
Worksheet on TG series - Type plates

What is the vehicle identification number of the TG vehicle?
Where is the type plate with the VIN located on the vehicle?
Where else can the chassis number be found on the vehicle?
What is the short vehicle number of the vehicle, and where can it be found?
Where was the vehicle manufactured?

Vienna ( )
Salzgitter ( )
Munich ( ) Steyr ( )
In what period was the vehicle built?
Find the type plates of the following components on the vehicle and enter the
specified data in the table:
Unit
Manufacturer
Type
MAN Item number
Front axle
Drive axle
Leading/trailing axle
Gearbox
Air reservoir, circuit 2
1.1
Worksheet on cab tilting and engine type plate
Where can the information plate shown above be found on the vehicle?
Describe the meaning of the individual symbols shown on the information plate.
1.
2.
3.
4.
5.
6.
7.
8.
Tilt the cab of the training vehicle and note the information on the engine type plate.
MAN - Werk Nrnberg
Typ
Motor-Nr. / Engine-no
N I / N II
3.1
Station 1 / Tasks on MAN Intranet and MANWIS
Station 2 / Tasks for vehicle TGX
Station 3 / Tasks for vehicle TGA
Time for practical work tasks at the stations

For each station and group: 90 minutes
Arbeitsblatt 4 LF-02a Intranet und Fahrzeuge-en.doc
4.1
Station 1 / Tasks on MAN Intranet and MANWIS

Task 1:
Which MAN item number refers to the maintenance manual for the TGX in German?
Item number:
Task 2:
Which MAN item number does the sticker for ProFit Check II have and how many stickers
are supplied for the order quantity 1?
Item number / Quantity:
Task 3:
Which edition of the A 16 Repair Manual is the current one at present?
Edition:
Task 4:
Where can the A16 be found ? Describe the path on the MAN intranet with the
corresponding keywords.
Path:
Task 5:
Which Euro standards do these 3 engines have: D2066LF18, D0834LOH50, OM 502LA ?
Euro standards:
Task 6:
Which wheel configuration does the vehicle type HW6 have?
Wheel configuration:
Task 7:
Which important information is provided in 812AT?
Topic:
4.2
Task 8:
Is there a Service Information for maintenance of the gearbox 6AS-850?
Note the SI number:
Task 9:
Enter the word AdBlue as a search term for the Service Information Bulletins.
Which SI numbers were found, and what were their contents?
Note the numbers and briefly summarise the SI descriptions.
Task 10:
You require an EDC circuit diagram for the training vehicle.
Find the function diagram number through the MAN basic vehicle data.
In which planning period was the vehicle built?
Note the function diagram number:
Task 11:
Have the diagram displayed using the EZIS application. How many sheets does the circuit
diagram have? Briefly describe the procedure.
Number of circuit diagram sheets:
Procedure:
4.3
Task 12:
Open the "Wartungs- und Betriebsstoffempfehlung" ("Maintenance Recommendations and
Service Products") and search for products and works standards in the MAN service
products database.
MAN works standard
Manufacturer / Product name
341-Z5
3477
342-S1
Castrol CEO 3291 M
BP Lubricants (manufacturer)
Aqua-Concept GmbH
Liqui Moly Touring High Tech SHPD
4.4
Task 13:
Which checklists can be found in MANWIS and what scope of maintenance work do they
cover?
Note the list designations and the related item number for the vehicle type TGA.
List and item number:
Task 14:
MANWIS: For RME-operated CR engines, a purchase guarantee must be obtained for fuel
injection components.
What kinds of damage are covered by the purchase guarantee?
Task 15:
MANWIS: What valve clearance is prescribed for the engine D2868 LF02?
Intake:
Discharge:
EVB counterholder:
4.5
Station 2 / Tasks for vehicle TGX

Operation
Do the window lifters for raising and lowering the side windows have a one-touch
function?
Yes
No
What values can be shown on the display of the speedo?
Trip mileage, time, mph
Languages German/English
Under which menu item can you find "Diagnose" ("Diagnosis")?

Men Fahrzeug Fahrdaten - Diagnose (Menu Tractor vehicle Driving data - Diagnosis)
Men Fahrzeug Einstellungen - Diagnose (Menu Tractor vehicle Settings - Diagnosis)
Men Fahrzeug Kontrolldaten - Diagnose (Menu Tractor vehicle Monitoring data - Diagnosis)
Which control units can be selected for fault finding under the menu item "Diagnosis"?
All control units that are installed in the vehicle
All control units that have a fault entry
Set the service pre-information value to the maximum possible display value. (Men
FahrzeugEinstellungenVorinfo-Service)
(MenuTractor
vehicleSettingsPre-info
Service) What is the maximum value?
How many menu items can be selected for the telephone "Settings"?
1
Under which menu item is the daytime lights function activated?

Men Fahrzeug Anzeige aus - Tagfahrlicht (Menu Tractor vehicle Display off - Daytime light)
Men Fahrzeug Einstellungen - Tagfahrlicht (Menu Tractor vehicle Settings - Daytime light)
Men Fahrzeug Kontrolldaten - Tagfahrlicht (Menu Tractor vehicle Monitoring data - Daytime light)
How long does it take before the steering wheel adjustment mechanism locks again
after steering wheel adjustment?
How long does it take until the rear view mirror automatically travels back to its basic
setting after it has been swivelled out?
4.6
Work outside the cab

How many screws have to be undone in order to swivel up the main headlight?
1 screw
3 screws
4 screws
5 screws
Swivel out the main headlight and check the bulb of the direction indicator. What is the
designation of this bulb?
P 0211
Osram 21 W
PY 21
What colours do the two connectors for the headlight power supply have?
red/yellow
white/red
grey/yellow
grey/red
What is the power output of the cornering light?

21 Watt
55 Watt
70 Watt
140 Watt
At what step height is the fastening screw for the lower light band located?
bottom step
middle step
top step
In which direction must the mirror glass be pushed when it is removed?

to the right
down
up
4.7
Work in the cab
Open the cover panel of the central electrical system (ZE) and determine the spare part
number of the ZE.
81.27444.6074
81.25444.7064
81.25444.6074
Where is the bass speaker of the radio system located?

under the bunk
under the seat
in the dashboard
How many screws have to be undone in order to remove the radio?

1 screw
2 screws
6 screws
Where is the socket X 200 located?
Can the ZE be folded out on the TGX / S?

How many screws have to be undone?
Find the installation locations for the AdBlue filters and note these.
Under what conditions is it possible to tilt the cab of the training vehicle?
4.8
Station 3 / Tasks for vehicle TGA

Task 1:
Read out the complete diagnostic memory by means of MAN-Cats and save the data on a
data medium. Which data media can be used?
Task 2:
What must always be done after reading out the complete fault memory?
Task 3:
Determine the installation locations of all control units in the vehicle and name the control
units with their assigned vehicle components.
Task 4:
Program the M1 and M2 buttons of the ECAS remote control and extended after-running
for the air suspension. Note the procedure.
4.9
Task 5:
Carry out an emergency start on the vehicle. Note the procedure that has to be followed.
Task 6:
What dangers exist if an emergency start is performed?
Task 7:
Remove the ignition lock and install it again. How do you proceed?
Task 8:
Carry out a lighting test and describe the procedure.
Task 9:
Which lights are not activated in the test?
4.10
Overview of equipment sorted according to G numbers

G 1. Compressors
G 2. Pressure regulators
G 3. Antifreeze devices
G 4. Multi-circuit protection valves
G 5. Pressure limiting valves/safety valves
G 6. Overflow valves
G 7. Service brake valves
G 8. Parking brake valves
G 9. Precharge valves
G 10. Diaphragm/piston cylinders
G 11. Double brake cylinders
G 12. Spring-loaded cylinders
G 13. Shutoff valves
G 14. Relay valves
G 15. Pressure ratio valves
G 16. Brake force regulators
G 17. Trailer control valves, 2-line
G 18. Trailer control valves, 1-line
G 19. Coupling heads, 2-line
G 20. Coupling heads, 1-line
G 21. Two-way valves
G 22. Quick-release valves
G 23. Non-return valves
G 24. Breather valves
G 25. Dewatering devices, air dryers
G 26. Differential pressure switching valves
G 27. Line filters, noise dampers
G 28. Shut-off cocks
G 29. Coiled hoses
G 30. Brake cables
G 31. Metal bellows
G 32.
G 33.
G 34.
G 35.
G 36.
G 37.
G 38.
G 39.
G 40. Tyre pressure valves, automatic
G 41. Tyre pressure valves, manual
G 42. Switching valves
G 43. Rim valves
G 44. Wheel bleeder valves
G 45.
G 46.
G 47.
G 48.
G 49.
G 50. Air reservoirs

G 51. Drain/dewatering valves
G 52. ALB test valves
G 53. Filler connections
G 54. Test connections, pneumatic
G 55. Pressure switches, pneumatic
G 56. Compressed air cylinders
G 57. Pressure gauges
G 58. Warning indicators
G 59. Pressure switches, hydraulic
G 60. Mechanical switches
G 61. Solenoid valves, filling
G 62. Solenoid valves, venting
G 63. Solenoid valves, SA
G 64.
G 65. Load/no-load valves
G 66. Pressure sensor valves, electrical
G 67. Pressure control valves (ABS)
G 68.
G 69. Actuator elements for air spring valves
G 70. Air spring valves
G 71. Switching valves WLS
G 72.
G 73. Electro-pneumatic valves for electronic air
suspension
G 74. Control parts for electronic air suspension
G 75.
G 76.
G 77.
G 78.
G 79.
G 80. Main hydraulic cylinders
G 81. Compensating reservoirs
G 82. Test connections, hydraulic
G 83. Wheel brake cylinders, hydraulic
G 84. Brake force regulators, hydraulic
G 85. Pressure ratio valves, hydraulic
G 86.
G 87.
G 88.
G 89.
G 89.
G 90.
G 91.
G 92.
G 93.
G 94.
G 95.
G 96.
G 97. Hoses
G 98. Signs, symbols
G 99. Miscellaneous

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Service Training

2009 MAN Nutzfahrzeuge Aktiengesellschaft

Frame / Running gear

Programme for TG Series - General

Introduction and presentation of TG series

Structure and presentation of service and maintenance literature,

including online versions

Frame design, including cab suspension, springs, axles, brakes,

Engine range for TG series with fuel systems, EGR

Gearshift variants (Kongsberg and cable pull)

Gearbox variants according to model series

Discussion of practical work / Farewell / Online assessment

Development history of the TG series

TGA / TGS / TGX

Vehicle identification number VIN

LF-02a[1]. TG-allg.-01-Einfhrung-0805 FH-en.doc

LF-02a[1]. TG-allg.-01-Einfhrung-0805 FH-en.doc

Development history of the TG series

LF-02a[1]. TG-allg.-01-Einfhrung-0805 FH-en.doc

LF-02a[1]. TG-allg.-01-Einfhrung-0805 FH-en.doc

LF-02a[1]. TG-allg.-01-Einfhrung-0805 FH-en.doc

TGA / TGS / TGX

LF-02a[1]. TG-allg.-01-Einfhrung-0805 FH-en.doc

Vehicle Identification No.

modified vehicle identification number.

The vehicle identification number now has the following format:

Difference compared with previous vehicle identification number (up to

LF-02a[1]. TG-allg.-01-Einfhrung-0805 FH-en.doc

World Manufacturer Identifier (WMI)

Type code number

Filler characters "ZZ" (no significance)

Check character introduced as from 01.10.2003:

Model year, see overview on Page 1.10

Plant code (assembly line), see overview on Page 1.10

Characters 12 to 17 Sequential number, line-dependent:

LF-02a[1]. TG-allg.-01-Einfhrung-0805 FH-en.doc

LF-02a[1]. TG-allg.-01-Einfhrung-0805 FH-en.doc

Model year code:

MAN Sonderfahrzeuge AG, Vienna, Austria

MAN Steyr AG, Steyr, Austria

MAN Trkiye A.S., Ankara, Turkey

MAN Trucks & Buses sp. z o. o., Starachowice, Poland

MAN ERF UK Ltd., Swindon, Great Britain

Neoplan Bus GmbH, Stuttgart, Germany

Former working partnership MAN-VW (G-series)

analogous to 1 and 2 for model years 2003 to 2009

01.07.2010 to 30.06.2011 etc.

Salzgitter, Germany (Bus)

Salzgitter, Germany (Bus)

Starachowize, Poland (Truck, Bus)

Salzgitter, Germany (Truck)

Salzgitter, Germany (Bus)

Salzgitter, Germany (Bus)

Munich, Germany (Truck)

Vienna-Liesing, Austria (Truck, Bus)

Munich, Germany (Truck)

Tarnowo Podgorne, Poland (Bus)

Salzgitter, Germany (Bus)

Ankara, Turkey (Bus)