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 1

Documentation 2

Frame / Running gear 3

Drivetrain 4

Cab operation 5

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

1 Introduction and presentation of TG series 3.0 hours

2 Structure and presentation of service and maintenance literature,

including online versions

5.5 hours

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

trailer equipment

8.0 hours

4 Engine range for TG series with fuel systems, EGR 4.5 hours

5 Clutch 2.0 hours

6 Gearshift variants (Kongsberg and cable pull) 1.25 hours

7 Gearbox variants according to model series 2.5 hours

8 Operation of TG vehicles 2.5 hours

9 Group work 6.0 hours

10 Discussion of practical work / Farewell / Online assessment 0.75 hours

Total time: 36,00 Hrs.

LF-02a[1]. TG-allg.-01-EinfÃ¼hrung-0805 FH-en.doc 1.1

Development history of the TG series 3

TG series 4

Series overview 4

TGL 4

TGA / TGS / TGX 6

Vehicle identification 7

Vehicle identification number VIN 7

Vehicle number 9

1.2 LF-02a[1]. TG-allg.-01-EinfÃ¼hrung-0805 FH-en.doc


Development history of the TG series

1840 1850 1900 1950 2008


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.


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.


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 TGX


Vehicle identification

Vehicle identification number VIN MAN Nutzfahrzeuge Aktiengesellschaft

Service Bulletin

Organisation Date 27.07.1999

Publisher VSTT

SI Number 442SM

Vehicle Identification No.

Modified vehicle identification number

Since 1st July 1999, vehicles have been delivered with a

modified vehicle identification number.

The vehicle identification number now has the following format:

Example: W M A H 0 5 Z Z X 3 K 0 0 1 0 2 8

Characters 7 to 8 Filler

character "Z"

Character

10

Character

11

Characters

12 to 17

Characters 4

to 6

Characters 1

to 3 Check

Character 9

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.


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.


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).


WMA

MAN Nutzfahrzeuge AG

VA0 (zero) MAN Sonderfahrzeuge AG, Vienna, Austria

VAN MAN Steyr AG, Steyr, Austria

NMA MAN Türkiye 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

World Manufacturer Identifier:

WVM Former working partnership MAN-VW (G-series)

Y 01.07.1999 to 30.06.2000

1 01.07.2000 to 30.06.2001

2 01.07.2001 to 30.06.2002

3 to 9 analogous to 1 and 2 for model years 2003 to 2009

A 01.07.2009 to 30.06.2010

Model year code:

B 01.07.2010 to 30.06.2011 etc.

B Salzgitter, Germany (Bus)

C Salzgitter, Germany (Bus)

F Starachowize, Poland (Truck, Bus)

G Salzgitter, Germany (Truck)

H Salzgitter, Germany (Bus)

J Salzgitter, Germany (Bus)

K Munich, Germany (Truck)

L Vienna-Liesing, Austria (Truck, Bus)

M Munich, Germany (Truck)

R Tarnowo Podgorne, Poland (Bus)

S Salzgitter, Germany (Bus)

T Ankara, Turkey (Bus)

W Salzgitter, Germany (Truck)

Y Steyr, Austria (Truck)

3 Stuttgart, Germany (Neoplan, Bus)

4 Pilsting, Germany (Neoplan, Bus)

5 Plauen, Germany (Neoplan, Bus)

Plant code:

6 Ehrenhain, Germany (Neoplan, Bus)

LF-02a[1]. TG-allg.-02-Dokumentation-0805 FH-en.doc 2.1

Documentation 3

Applications of MAN contractual partners 3

Access to the intranet 4

Target group information for sales staff 5

Repair and maintenance manuals 5

Basic workshop equipment 8

Service Information Bulletins 9

Type code 15

Basic vehicle data 16

Information portal EZIS® 19

EZIS via intranet 20

Definition of the most important abbreviations 22

2.2 LF-02a[1]. TG-allg.-02-Dokumentation-0805 FH-en.doc


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.


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.


Target group information for sales staff

Selection area for Service - After Sales

Repair and maintenance manuals

Click hyperlink.

Service Literature Service Information Service Training CenterMAN Cats Service Desk

Service Literature


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.


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 A Clutch B Manual gearbox - splitter unit, Eaton, Fuller, ZF C Transfer case E Driven, non-steered axle (rear axle), twin-tyred dummy axle F Driven, steered axle (front axle) G Nocn-driven axle (front, leading, trailing axle) H Circuit diagrams, electrical system K Hydraulic steering (steering aids) L Electrical components N Brake systems, air suspension P Axle location, suspension R System description T Cab U Chassis / Frame V Removing/installing major components Y Seats Recommendations on towing, diesel particulate filter, Beka central lubrication

Heating, air-conditioners


Basic workshop equipment The screen show below also includes the hyperlink "Empfohlene Grund-ausstattung 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)"


Service Information Bulletins Under this link you can find all the latest information about our systems and sub-

systems. 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 hyperlink.

It is currently possible to choose between twenty-six languages in the screen

shown below.

Service Information

Select the desired user language by clicking the corresponding button with the mouse.


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 Information Bulletins Service Bulletins Data collections Forms Measurement sheets Checklists Exemplary Fluke diagrams

Service Information for industrial and marine engines

General overview

New service

General overview

General overview

General overview

§ 29 StVZO (German Road Traffic Regulations) and official texts

Supplier codes


Service Information Bulletins (SIs) are produced and classified based on vehicle

assemblies.

Group Topic/Systems Sub-systems

0 Engine Fuel, intake, exhaust, cooling systems. Air compressor

2 Electrical system, instruments

3 Gearbox, axles Clutch, propshafts and mounts/bearings

4 Chassis Steering, pedal mechanism excluding brake, vehicle lubrication, air suspension

5 Brakes Wheel-side brake components, actuation

6 Body

10 General, technical publications Unit and type identification, legal issues, warranty

11 Service products

12 Maintenance, vehicle handling, special tools

13 Accident prevention, road safety, § 29 / safety inspection

Current topics

Current topics

Service Bulletins

Current SIs for the workshops

Data collections

Tables and value collections Tightening torques, fault codes, etc.

Fluke Exemplary Fluke diagrams

Forms Forms for applications, checklists, goodwill

Measure-ment sheets

Special test and measurement sheets

Neoplan Neoplan

Checklists Checklists for maintenance Vehicles before TG

Product development

Preview of developments

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)


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.


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 can be entered here.

Search

Search term

Start and confirm search with the Search button.


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.


Type code

Information about MAN type codes is available in the sections MAN Home

Vertrieb weltweit.Vertrieb weltweit (Worldwide sales).

All MAN type codes are listed in these data sheets (screenshot below)

Type codes


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.


Another window opens after you have clicked the "Search" option with the left

mouse button.

1

2 3

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").


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.


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!


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


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......

Perform search Reset


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)

LF-02a[1]. TG-allg.-03-Rahmen-Fahrwek-0805 FH-en.doc 3.1

Frame / Running gear 3

Frame design 3

Frames for the TGL series 3

Frames for the TGM series 3

Frames for the TGA / S / X series 4

K cross member 5

Front end 5

Rear end cross member 7

Coupling equipment 8

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

MAN HydroDrive® 27

Steering knuckle 29

HUB UNIT 29

Steering gear 30

Adjustment with skew steering wheel 31

3.2 LF-02a[1]. TG-allg.-03-Rahmen-Fahrwek-0805 FH-en.doc

Brake systems 32

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 41

Sectional view SN 6 / SN 7 42

Functional description 43

Brake clamping 43

Brake release 43

Brake adjustment 44

Disc brake LUCAS-D-Elsa 45


Frame / Running gear 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

8 t 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


Frames for the TGA / S / X series

Tubular cross Rolled

longitudinal member, TM500

Open front end

Frame Hole spacing same for all

variants

Rolled longitudinal members made of

high-strength steel QSTE 500 TM,

270 mm throughout

Frame reinforcements

Higher flexural strength, low frame

height

Reinforcements between the cross

members and in the middle section

of long wheelbases

Tubular cross members

Spaced holes in the front

section

Open front end

make the frame torsionally rigid and

ensure minimum load transfer to

body

Simple assembly of the different axle

guides

Single-piece rear end member,

folded

Installation of large-area radiators

possible


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.

Front end

The open front end permits installation of large-area radiators

K cross member


Front end with underride guard

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.

Maximum crash safety for car passengers thanks to

underride guard

Thread for towing lug

Deformation element to absorb energy


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


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 3

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


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


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.


Equipment on the frame for tractor units available ex-works

Ladder behind cab

Storage box on left Walk-on platform up to fifth wheel


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.


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.

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.

Level-control

valve

mechanical

external


Spring always presses level control

mechanism against the upper end stop

of the air spring

Spring extended, venting

position, valve to output open

Lever for valve opening at right

limit position, valve open

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


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.


Suspension Leaf-spring suspension

TGL

Type Front spring Rear spring or

7.5 t 1-leaf parabolic 1-leaf parabolic 2-bag air

8 t 2-leaf parabolic 1+1-leaf parabolic 2-bag air



View of single-leaf spring TGL

TGM


15 t 4x2 2-leaf parabolic 2-leaf parabolic 4-bag air

18 t 4x2 2-leaf parabolic

4-bag air

1+1-leaf parabolic 4-bag air

13 t 4x4 2-leaf parabolic 4-bag air

18 t 4x4 2-leaf parabolic 2+1-leaf parabolic

26 t 6x4 2-leaf parabolic 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: Leaf-spring suspension

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


Air suspension:

TGL

On TGL vehicles, an air suspension

system can be installed only on the rear

axle.

TGM


15 t 4x2 2-leaf parabolic 2-leaf parabolic 4-bag air

18 t 4x2 2-leaf parabolic

4-bag air

1+1-leaf parabolic 4-bag air

13 t 4x4 2-leaf parabolic 4-bag air

TGA / S / X Air suspension 2-bag (- 8.5 t)

Air suspension 4-bag (- 11.5 t) (- 13.0 t)


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).


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.


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


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.


Axles

Overview of axle type designations

Front axles

With leaf-spring suspension:

With air suspension:

VA7 - 07 50 Input torque x~100 (Nm)

Nominal axle load (t)

Series

VA = Driven front axle

HY - 11 75 Input torque

x~100 (Nm)


H9 - 13 120 Input torque x~100 (Nm)


Series

H = Planetary rear axle

VOK-08 Nominal axle load (t)

VOK = Non-driven front axle with

drop

VO = Straight front axle

NO = Rigid trailing axle

NOL = Steered trailing axle

VP-09 Nominal axle load (t)

V9 - 42 L Steerable

Nominal axle load (kg x~100)

Series

HY-13 50 Gross train weight (t)


HY = Hypoid rear axle

HYD-13 70 Double hypoid rear axle

with drive-through

HP-13 52 Gross train weight (t)



Rear axles

With leaf-spring suspension:

With air suspension:

Leading and trailing axles

Leading axle (steered)

Trailing axle (steered)


Trailing axle (not steered, for twin tyres)

Axle overview according to series

Overview of TGL axles

Front axle Rear axle

Drop: 40 mm


Overview of TGM axles Front axle Rear axle

Overview of TGA / S / X axles Front axle Rear axle


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.


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.

High-pressure connection

Leak oil wheel

Leak oil wheel hub

Wheel bearing

High-pressure connection

Throttle ring


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.


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).

Fahrzeug-tacho

Fehler-lampe

DiagnoseEl

ektr

onis

ches

Steu

erge

rät

Lenkwinkel-sensor

Raddrehzahl-sensor

Druck-versorgung

Steuerventile

Stellzylinder

Lenkwinkel-sensor

Versorgung 24VFahrzeug-tacho

Fehler-lampe

DiagnoseEl

ektr

onis

ches

Steu

erge

rät

Lenkwinkel-sensor

Raddrehzahl-sensor

Druck-versorgung

Steuerventile

Stellzylinder

Lenkwinkel-sensor

Versorgung 24V

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.


ZF 8099- Servocom

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.

When replacing the steering gear, fill

sleeve with oil ATF MAN 339 Type D/F.


Brake systems Examples

Exam

ple:

TG

A E

BS

Kno

rr 2

.2/2

.3



Exam

ple:

TG

-X/S

EB

S K

norr

5



Exam

ple:

TG

-L/M

EB

S W

abco

2



System description

E B S

Electronic Brake System

Sub-functions

E P B Electro-Pneumatic

Brake system

⇒ Fast response

⇒ Short braking

distances

⇒ Low wear

A B S Antilock Braking

System

⇒ No wheel locking

⇒ Wheels steerable

when braking

⇒ Continuous brake

deactivation

A S R Anti Slip

Regulation

⇒ Traction control

prevents wheel spin

when accelerating

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.


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.


Lever

Adjusting unit

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.

Wear sensor

Chain wheel

Roller chain

Threaded tube Roller bearing

Cover unit

Compression spring

Adapter

Brake disc

Shaft

Thrust piece

with bellows


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.


Sectional view SN 6 / SN 7

Chain wheel

Roller chain

Threaded tube

Roller bearing

Cover unit

Compression spring

Brake calliper

Guide bushing

Thrust piece

with bellows

Wear sensor

Brake carrier

Brake disc

Brass bushing

Brake calliper

Retaining bracket


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.


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.

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!

Key

6 Lever arm

9 Threaded spindle with thrust

piece

10 Chain

12 Shift fork

13 Inner sleeve

14 Ball ramp

15 Spring


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

LF-02a[1]. TG-allg.-04-Antrieb-0805 FH-en.doc 4.1

Drivetrain 3

Overview of engine variants for the TG series 3

TGL engines 3

TGM engines 4

TGA / S / X 5

Engine type plate 7

Fuel injection systems 8

Overview of EDC MS 6.1 8

Schematic fuel circuit diagram for EDC MS 6.1 10

Common Rail 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



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

4.2 LF-02a[1]. TG-allg.-04-Antrieb-0805 FH-en.doc



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


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 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) 1900 rpm

1550 Nm 1000 - 1400 rpm

D2066 LF13 CR (4-V) 257 kW (350 hp) 1900 rpm

1750 Nm 1000 - 1400 rpm

D2066 LF12 CR (4-V) 287 KW (390 hp) 1900 rpm

1900 Nm 1000 - 1400 rpm

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

2100 Nm 1000 - 1400 rpm

SCR mixer

EURO 5 with SCR

D2066 LF22 CR (4-V) 294 KW (400 hp) 1900 rpm

1900 Nm 1000 - 1400 rpm

D2066 LF21 CR (4-V) 321 KW (437 hp) 1900 rpm

2100 Nm 1000 - 1400 rpm

D26 engines EURO 4 with EGR + PM-KAT

D2676 LF01 CR (4-V) 353 kW (480 hp) 1900 rpm

2300 Nm 1050 - 1400 rpm

SCR mixer

EURO 5 with SCR

D2676 LF12 CR (4-V) 353 KW (480 hp) 1900 rpm

2300 Nm 1050 - 1400 rpm

D2676 LF11 CR (4-V) 397 KW (540 hp) 1900 rpm

2500 Nm 1050 - 1400 rpm


D28 engines Only for TGA D2866 LF23 (4-valve + EGR)

228 kW (310 hp) 1800 - 1900 rpm 1500 Nm 900 - 1300 rpm

D2866 LF24 (4-valve + EGR)

265 kW (360 hp) 1800 - 1900 rpm

1700 Nm 900 - 1400 rpm

D2866 LF25 (4-valve + EGR)

301 kW (410 hp) 1900 rpm

1850 Nm 900 - 1300 rpm

D2876 LF03 (4-valve + EGR) 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) 1900 rpm

2700 Nm 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) 1900 rpm

2700 Nm/3000 Nm 1200 - 1500 rpm


Engine type plate

MAN - Werk Nürnberg

Typ

Motor-Nr. / Engine-no N I / N II

D2676 LF 03

5459170015B2E1 N I / N II Feld

Engine type designation

e.g. D2676 LF 03

D Fuel type, diesel

26 + 100 = bore diameter, e.g. 126 mm ∅

7 Designates the stroke 6 = 155 mm, 7 = 166 mm

6 Number of cylinders 6 = 6 cylinders, 0 = 10 cylinders, 2 = 12 cylinders

L Type of charging, Turbocharging with charge air cooling

F Engine installation position:

F Truck Forward-control vertical engine

OH Bus Rear-installation vertical engine

UH Bus Rear-installation horizontal engine

03 Engine variant; particularly important for spare part supply, technical data

and setting values.


Fuel injection systems

Overview of EDC MS 6.1

Fahrpedal

Lenkstock-schalter

Bremse

Kupplung

Kombiinstrument,Warnlampe

Motorbremse

Geschwindigkeit

Fahrzeug-führungsrechner

DatenverbindungMotor-CAN-Bus

Triebstrang CAN-Datenbus

Instrumenten CAN-Datenbus

MS61ALG2.CDR

Fahrerhaus

Drehzahl 1 Drehzahl 2

Nadelbewegungs-fühler

Ladedruck

Wasser-temperaturKraftstoff-

temperatur

Ladeluft-temperatur(Euro3)

Kraftstoff-druck

SteuergerätEDC MS6.1

Öldruck

Abgas- Rückfüh-rungsventil(EURO3)

Klemme 30

Klemme 15

Motor

Motorseitiges


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-width-

modulated) signal.


Schematic fuel circuit diagram for EDC MS 6.1


Common Rail

Overview of EDC 7

Vehicle M anagement

omputer C (FFR)

Rotational speed sensor

Camshaft sensor

Pedal travel sensor

Boost pressure sensor

Operating unit

Water -Temperature

Fuel pressure

ahead of filter

K li

ne

CANControl unit

Term

inal

15

Term

inal

30

Rail pressure sensor

EGR actuator cylinder

Injector

High-pressure pump

FGB/FGR-switch

Clutch

Brake


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 cam-

controlled 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.


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


Schematic fuel circuit diagram EDC 7 Common Rail on D20 Euro 3

High-pressure pump with gear

delivery pump

Flame start

system

KSC (fuel

service centre) Injector

Overflow valve in return line

Return channel in cylinder head

Rail pressure sensorPressure limiting valve


Legal introduction dates of emission standards

2004 2005 2006 2007 2008 2003 2009

10/2006

10/2005

Euro 4New types, incl. OBD 1 *) Durability In use compliance

10/2008

10/2009

Euro 4New registrations, incl. OBD 1 *)

Durability In use compliance Euro 5

New types, incl. OBD 2 **)

Euro 5New registrations, incl. OBD 2 **)

OBD = On Board Diagnosis

*) 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

Exhaust gas

External cooled exhaust gas recirculation

40 °C

600 °C

• High temperature of cylinder charge

• Low retention rate

Required NOxvalues are not achieved

additionally: • Lower fuel

injection rate• Later start of

injection

• Worse efficiency • High consumption • Oil contamination

40 °C

Charge air

160 °C

Cooled exhaust gas

• Lower temperature of cylinder charge

• High recirculation rate

Required NOxvalues are achieved

• High efficiency • Low consumption • Clean oil

• No further measures are necessary

• Euro 4 potential

EURO 3

EURO


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.

Air filter

Engine

EGR cooling

EGR valve

Pressure peak

Charge-air


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.

Air filter

Engine

EGR cooling

EGR valve

PM-

KAT®

Pressure peak valves

Charge-air


Schematic diagram of the PM-KAT

Chemical conversion in the catalytic converter

VV

PP

VV PPrree--ooxxiiddaattiioonn ppllaattiinnuumm ccaattaallyyttiicc ccoonnvveerrtteerr:: 22NNOO

PP PPaarrttiiccuullaattee mmaatttteerr sseeppaarraattoorr:: 22NNOO22++ CC CCOO22++

MAN PM-KAT® system in the TGA

PM separator

Pre-


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® mixer

O-CAT R-CAT

Urea metering system (HDS)

AdBlue®

tank

O-CAT NH3 oxidation 44NNHH33 ++ 33OO 22NN22 ++ 66HH22OO

R-CAT NOx reduction 4

AdBlue® mixer Ammonia formation C

4NNOO ++ OO22 ++ 44NNHH33 44NN22 ++ 66HH22OO

COO((NNHH22))22++HH22OO 22NNHH33 ++ CCOO2 2

MAN AdBlue system for Euro 5 in TGA / S / X

Injection

of AdBlue

AdBlue mixer Reduction catalytic converter Oxidation catalytic converter


Installation on engine

Exhaust turbocharger

Metering valve

Urea nozzle AdBlue mixer

Exhaust temperature sensor


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 spring-

loaded 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.


Clutch Clutch on the D08 engine for TGL

Clutch MF-362 for D0834 LFL

Travel sensor

Venting

connections

Connection for travel sensor Travel sensor The travel sensor is calibrated with MAN- CATS

The clutch is pushed upon operation!

This clutch has only a clutch

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.


Clutch MFZ-395 for D0836 LFL with 6-cylinder engines

Note: As from 6-cylinder engines, clutch

operation is by pulling!!

With clutch booster for manual

gearboxes and clutch 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.


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.

Pressure distributor

Double master cylinder

Old shift lever knob design New shift lever knob design

Splitter unit switch

Range unit switch

Comfort Shift

OFF

Range unit ON

Splitter unit

Clutch actuation for Comfort Shift


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

Hydraulic slave cylinders

Hydraulic master cylinder in the cab

Disconnection point Cab frame

Hose to the compensating reservoir

Selection

Shifting


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.


Gearbox variants

TGL

ZF ECOLITE

S5-42 OD i = 5.72 - 0.76 67 kg

5F/1R (150 hp)

6 S 850 OD i = 6.72 - 0.79 111 kg

6F/1R (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 - 1.00 154 kg

9F/1R (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 - 0.81 190 kg

12F/1R (240-330 hp)


TGM

EATON

FS 8309 DD i = 12.6 - 1.00 154 kg

9F/1R (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 - 0.81 190 kg

12F/1R (240-330 hp)

TGA / S / X

ZF ECOSPLIT

16S182 OD i = 13.80 - 0.84 TGA

16F/2R 289 kg 310/350/410 hp

16S192 DD i = 16.41 - 1.00 TGA

16F/2R 317 kg 310/360/410 hp

16S222 OD i = 13.80 - 0.84 TGA

16F/2R 317 kg 310/390/430/460 hp

16S222 DD i = 16.41 - 1.00 TGA

16F/2R 319 kg 310/360/410/460 hp

16S252 OD i = 13.80 - 0.84 TGA 16F/2R 319 kg 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 660 hp

i = 12.33 - 0.78 Heavy-duty tractor


Design of the ZF gearboxes TipMatic mid / TipMatic (Function diagram) 6-cylinder

Second countershaft

Force

Reaction force

Main shaft Countershaft

The gearbox has a two-countershaft design.

Reaction force

The reaction forces cancel each other out at the main shaft

bearing

Internal design of the ZF gearboxes TipMatic mid / TipMatic

Three-speed unit

with reverse gear

Reverse gear

Range unit

Output flange

Gearbox

brake

Splitter unit

The gearbox is designed as a range-change gearbox.


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: 0.983 Off-road gear: 1,607

Weight: 143 kg 10.xxx 14.xxx/18.xxx

TGL TGM


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 G252/G253

On-road gear: 1.007 0.981

Off-road gear: 1.652 1.583

Weight: 360 kg 394 kg

up to 430 hp 41.480

TGA 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 a

Cab operation 2

The CAN bus structure 2

Operation at driver's workplace 4

Cab front panel 6

Inspection and maintenance locations 7

Cab tilt mechanism 8

Cab tilting - hydraulic 9

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 LF-02a[1]. TG-allg.-05-Fahrerhaus-0805 FH-en.doc


Drivetrain CAN

CAN = Controller Area Network: Drivetrain CAN Engine CAN

Instrument CAN

Instrument CAN

Engine CAN

CAN Bus = control unit networking via data

lines Instrumentation

Vehicle management computer

Engine control

Central on-board computer

Transmission control

Retarder

Air suspension

Air management

Brake control

Tachograph

Operation at driver's workplace

TGL without multifunction steering wheel


TGA and TGL / TGM with multifunction steering wheel

TGS / X


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)


Inspection and maintenance locations

Filler neck for engine oil

Emergency release

connection for spring-type

Filler neck for windscreen

washer system

Compensating reservoir for clutch

and gearshift operation

Filler neck for coolant - exercise

caution when the engine is hot


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.


Cab tilting - hydraulic

21

1 Lever of reversing valve

2 Hexagon for fitting the wheel nut wrench

Caution: Always tilt the cab to its limit position!


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.


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.


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 selection

2. Mirror position Main mirror, passenger's side

Mirror heating JoystickMirror

preselectionleft / right

Window lifter

TG A version

Central locking

TG X / S version


Auxiliary air conditioning system

The auxiliary air conditioning system is completely integrated in the driving air-

conditioning 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

Evaporator unit Control and

distribution unit

Air-conditioning unit with heat sink

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.


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 air-

conditioning 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


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.


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.


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.


TipMatic gearbox operation

Range selector switch A434 - Cruise control / gearbox switch A429

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.

Pushbutton

Steering column


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)!


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 auto-matically 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


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!

D

DM

R1

RM

N

Neutral


Arbeitsblatt 1 LF-02a-en.doc 1.1

Worksheet on sales designations, wheel configurations and installation plates

What door designation does the training vehicle have?

Weight:

tput: Power ou

What cab type does the vehicle have?

hat wheel configuration does the vehicle have?

W

what RAL colour is the cab painted?

In

hat values are entered on the installation plate for the tachograph?

W

L: W: K:

hen was the tachograph inspection performed?

W

hat K value applies to the vehicle (exhaust-emission check)?

W

hich item number does MAN prescribe for the air filter insert, and what

tic:

W

characteristic does the air filter insert have?

No.: Characteris


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


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 Nürnberg

Typ

Motor-Nr. / Engine-no N I / N II

Arbeitsblatt 4 LF-02a Intranet und Fahrzeuge-en.doc 4.1

Station 1 / Tasks on MAN Intranet and MANWIS 2

Station 2 / Tasks for vehicle TGX 6

Station 3 / Tasks for vehicle TGA 9

Time for practical work tasks at the stations For each station and group: 90 minutes

4.2 Arbeitsblatt 4 LF-02a Intranet und Fahrzeuge-en.doc

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:


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:


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


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:


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")?

Menü – Fahrzeug – Fahrdaten - Diagnose (Menu – Tractor vehicle – Driving data - Diagnosis)

Menü – Fahrzeug – Einstellungen - Diagnose (Menu – Tractor vehicle – Settings - Diagnosis)

Menü – 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. (Menü–

Fahrzeug–Einstellungen–Vorinfo-Service) (Menu–Tractor vehicle–Settings–Pre-info

Service) What is the maximum value?

How many menu items can be selected for the telephone "Settings"?

1 3 4 6

Under which menu item is the daytime lights function activated?

Menü – Fahrzeug – Anzeige aus - Tagfahrlicht (Menu – Tractor vehicle – Display off - Daytime light)

Menü – Fahrzeug – Einstellungen - Tagfahrlicht (Menu – Tractor vehicle – Settings - Daytime light)

Menü – 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?


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


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?


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.


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?

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

SERIE TG GERAL ANTERIOR.pdf

Documents

presentation of tg series

tg series general

tg series series overview

model series

vehicle variants

vehicle number

cab operation

model range