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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

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1.1

1.2

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Development history of the TG series

1840

1850

1900

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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

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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.

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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

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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.

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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

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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).

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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)

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)

Salzgitter, Germany (Truck)

Steyr, Austria (Truck)

Stuttgart, Germany (Neoplan, Bus)

Pilsting, Germany (Neoplan, Bus)

Plauen, Germany (Neoplan, Bus)

Ehrenhain, Germany (Neoplan, Bus)

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

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

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2.1

2.2

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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.

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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

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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

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

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

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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

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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

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Service Information Bulletins


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.

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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 Information Bulletins


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

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

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)
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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

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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.

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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

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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)

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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

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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").

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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

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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!

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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

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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

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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

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Frame / Running gear


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

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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

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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

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

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

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

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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

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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

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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

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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

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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

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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

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Equipment on the frame for tractor units available ex-works

Ladder behind cab

Walk-on platform up to fifth wheel


Storage box on left

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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

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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.

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

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

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

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.

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

3.15

Suspension
Leaf-spring 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

4x2 2-leaf parabolic

1+1-leaf parabolic

4-bag air

4-bag air

3.16

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

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

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

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

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

4x2 2-leaf parabolic

2-leaf parabolic

4-bag air

18 t

4x2 2-leaf parabolic

1+1-leaf parabolic

4-bag air

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)

3.18

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

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).

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

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

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

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

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

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

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

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

Nominal axle load (t)

Series

Series

Driven front axle

H = Planetary rear axle


HY-13 50

Gross train weight (t)

Non-driven front axle with

Nominal axle load (t)

drop
VO =

Straight front axle

NO =

Rigid trailing axle

NOL =

Steered trailing axle

HY =
HYD-13 70

Nominal axle load (t)

Hypoid rear axle

Double hypoid rear axle


with drive-through

HP-13 52
VP-09

Input torque x~100 (Nm)

Nominal axle load (t)

Nominal axle load (t)


VOK =

Input torque
x~100 (Nm)

VA7 - 07 50

VA =

HY - 11 75

Nominal axle load (kg x~100)

Gross train weight (t)


Nominal axle load (t)

Front axles

With leaf-spring suspension:

With air suspension:

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

3.23

Rear axles

With leaf-spring suspension:

With air suspension:

Leading and trailing axles

Leading axle (steered)

Trailing axle (steered)

3.24

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

Trailing axle (not steered, for twin tyres)

Drop: 40 mm

Axle overview according to series

Overview of TGL axles

Front axle

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

Rear axle

3.25

Overview of TGM axles


Front axle

Rear axle

Front axle

Rear axle

Overview of TGA / S / X axles

3.26

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

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.

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

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

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

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.

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

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

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

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.

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

3.31

Brake systems

Example: TGA EBS Knorr 2.2/2.3

Examples

3.32

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

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

3.33

Example: TG-X/S EBS Knorr 5


3.34

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

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

3.35

Example: TG-L/M EBS Wabco 2


3.36

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

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

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

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

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.

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

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

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

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.

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

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

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

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.

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

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

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

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.-03-Rahmen-Fahrwek-0805 FH-en.doc

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

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

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

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

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

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

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

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

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)
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

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

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.

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

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

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

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.

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

4.9

Schematic fuel circuit diagram for EDC MS 6.1

4.10

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Reduction catalytic converter


Oxidation catalytic converter
4.19

Installation on engine

Exhaust turbocharger

Exhaust
temperature sensor

Metering valve
AdBlue mixer

4.20

Urea nozzle

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

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.

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

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

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

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.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Air management

5.3

Operation at driver's workplace


TGL without multifunction steering wheel

5.4

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

TGA and TGL / TGM with multifunction steering wheel

TGS / X

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

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

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

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

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

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

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

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!

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

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

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

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.

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

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

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

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.

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

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

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

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.

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

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

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

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.

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

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

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

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)!

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

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

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

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

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

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

Arbeitsblatt 2 LF-02a-en.doc

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

Arbeitsblatt 3 LF-02a-en.doc

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

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

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:

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

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

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

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:

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

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

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

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

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

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

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

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.

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

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

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

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