Professional Documents
Culture Documents
MANTruck&BusAG
Postfach 50 06 20
D-80976 Mnchen
www.mantruckandbus.com
A MAN Group company
T rucknology mobile.
M
anual of Breakdown Assistance I Recovery I
Towing.
Editorial
We are delighted to present you our handbook
entitled "Trucknology mobile Breakdown
Assistance I Recovery I Towing".
It is intended to be used as a working manual, a
training document and a reference work for towing
and breakdown services, motor vehicle service
workshops and other interested vehicle operators.
Our experts from technology and sales hope that this
will provide you with a clear explanation of the evergrowing basic knowledge required to keep TGX, TGS,
TGA, TGM and TGL vehicles mobile even in the event
of damage. Also, it should provide information about
the correct procedures for removing these vehicles
from a possible accident location.
The recommendations for towing and recovery
measures assume that the personnel involved
have the necessary professional qualification and
knowledge of the regulations.
Publisher:
MANTruck&BusAG
Dachauer Strasse 667
D-80995 Mnchen
After Sales Documentation
Markus Jaser
Tel. +49 89 1580-3148
markus.jaser@man.eu
Central Testing Department
Jrg Friedrich
Tel. +49 89 1580-1418
joerg.friedrich@man.eu
Overview
Pioneering spirit has always been the driving force behind MAN engineers for
Brands
(Trucks, buses)
Self-image
Product description
II
Business units
Products
Trucks from 5.5 to 44t gross vehicle weight rating, with 110500kW
(150680PS), heavy special vehicles up to 250t gross combination weight
Inner-city buses, inter-city buses and coaches (complete buses and chassis)
Diesel engines for road, marine, rail vehicles and industrial applications up to
1800PS
Gas engines for natural gas (CNG), liquefied petroleum gas (LPG) and biogas
General services
Sales
regions
Vertriebsregionen
#DTSRBGK@MC
$TQNO@6DRS
$TQNO@2C
$TQNO@-NQC
$TQNO@.RS
&42
(ADQH@
EQHJ@
,HCCKD$@RS
RH@/@BHjB
+@R LDQHB@R
#HQDJSFDRBGES
Germany
Nuremberg (engines)
IV
Austria
Poland
South Africa
Turkey
Mexico
TRUCKS)
buses)
buses)
MAN history
A success story
Milestones
The history of MAN commercial vehicles spans a period of more than 100 years.
Between 1893 and 1897, Rudolf Diesel achieved his ingenious invention at MAN
in Augsburg.
The diesel engine heralded a new era of mobility. From the word go, MAN
shaped how progress would be made. It is a history with many highlights.
A success story which we consistently continue to this day.
2011
2010
2008
2006
2006
2005
2004
2003
2002
2001
2001
2001
2000
1999
1999
1995
"Truck of the Year" for the fourth time with the F2000
1994
1993
1990
1987
1980
1979
1978
1971
Takeover of Bssing-Automobilwerke
1955
1951
1924
1923
First direct injection for vehicle diesel engines ready for the market
1915
1897
VI
VII
Contents
General information . . . . . . . . . . . . . . . . . . 3
1.1
4.1
1.1.1 Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4.1.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.1.2 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2
Vehicle identification . . . . . . . . . . . . . . . . . . . . . 4
4.2
4.2.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . 9
2.1
4.3
Breakdown assistance . . . . . . . . . . . . . . . . . . . 51
Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3.5 Tow-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.2
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.4.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.1
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2
4.5
Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.3
3.3.3 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Appendix . . . . . . . . . . . . . . . . . . . . . . . . 145
5.1
6.1
6.2
5.2
6.3
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Notes
1 General information
1.1 About this handbook
1.1.1
Content
1.1.3
Technical status
1.1.4
Key to symbols
procedural instructions.
1.1.2
Liability
Registered trademarks
MAN HydroDrive
MAN TipMatic
MAN AdBlue
1 General information
1.2 Vehicle identification
1.2.1
Identifying characteristics
2); possibly with MAN HydroDrive front-axle drive in the TGX, TGS or TGA series
Suspension type, differentiated according to axles (e.g.
TGS with steel bumpers (mostly construction site vehicles, TGX similar)
1 General information
1.2 Vehicle identification
1.2.2
side
Display of the instrument panel (Vehicle Check data
Diagnosis Vehicle characteristic data Chassis no.);
for instrument panel see chapter 4.1 (TGX, TGS),
chapter 4.2 (TGA) or chapter 5.1 (TGL, TGM)
As barcode on a plate behind the front axle
1 General information
1.2 Vehicle identification
1.2.3
Vehicle number
The 7-digit vehicle number describes the technical equipment of the vehicle. The 1st to 3rd digits are a 3-digit code
as the type code. In the TGX series, the code ends with X
and in the TGS series, it ends withS. In the TGA series, the
code starts with H, whereas in the TGL and TGM series,
the code starts with N
For example:
03S-0002 on a vehicle in the TGS series
H06-2998 on a vehicle in the TGA series
N12-0022 on a vehicle in the TGL series
Locations
Official vehicle document (for German registration,
number 33 "Remarks")
Front right longitudinal member, ahead of the front axle
Type plate on the B-pillar on the co-driver's side
1 General information
1.2 Vehicle identification
1.2.4
Wheel formulae
Example: Semitrailer tractor TGS, two of four wheels driven, two wheels
steered (wheel formula 4x2)
Vehicle with MAN HydroDrive: Front wheel hub with hydraulic wheel hub
motor
1 General information
1.2 Vehicle identification
Wheel formula
Explanation
4x2
4x4
4x4H
Two-axle vehicle with two driven axles, front axle with hydrostatic drive
6x2 /2
6x2 /4
6x2-2
6x2-4
6x4/4
6x4-4
Three-axle vehicle, front axle and one rear axle driven, steered trailing axle
6x4H
Three-axle vehicle, front axle with hydrostatic drive, one driven rear axle
6x6
8x2-4
Four-axle vehicle, one driven axle, two steered front axles, non-steered trailing axle
8x2-6
Four-axle vehicle, one driven axle, two steered front axles, steered trailing axle
or four-axle vehicle with three rear axles of which two are steered as leading and trailing axles
8x4
Four-axle vehicle with two steered front axles and two driven rear axles
8x4/4
Four-axle vehicle with one front axle, one steered leading axle and two driven rear axles
8x4-4
Four-axle vehicle with one front axle, two driven rear axles and one steered trailing axle
8x6
Four-axle vehicle with two front axles (2nd driven) and two driven rear axles
8x8
Four-axle vehicle "all-wheel drive" with two front axles and two rear axles, all driven
1 General information
1.3 Safety instructions
1.3.1
1.3.2
Warning!
Damage to safety components can lead to traffic
accidents with serious consequences!
Danger!
Warning!
been damaged.
Caution!
Warning!
prevention of damage.
Safety components
Cardan shafts which were removed
10
General information
Notes
Note
This chapter contains information about
troubleshooting and jump starting. This information
applies to the TGX, TGS, TGA, TGL and TGM
series. For addition, detailed information about
breakdown assistance, refer to chapters 4.3 (TGX,
2.1.1
2.1.2
Fault messages
Warning!
The following tables are primarily used for
troubleshooting, and only provide procedural
instructions of a general nature! In case of specific
damage, the breakdown assistance personnel
must decide on the spot which measures are
appropriate. In particular with defects that impair
vehicle safety, the people involved must consider
conscientiously whether the broken-down vehicle
can drive to the nearest MAN Service workshop or
will have to be towed.
11
Driver's display
Symbol
Text message
Circ. 1, 2, 3, 4
pressure
too low
Reservoir pressureK3
Malfunction
electrical system
On-board computer
malfunction
Malfunction
veh. man. computer
Malfunction
engine ctrl. unit
Malfunction
gearbox ECU
Check lamps
Flashes
red
Flashes
red
Flashes
red
Meaning
Red
Red
Red
Yellow
Check fuse.
Check fuse.
Check fuse.
Check fuse.
Check fuse.
Flashes red
Flashes red
Flashes red
Flashes red
Procedure
Flashes red
Defective switch
haz.warn. lights
Flashes red
Check fuse.
Change bulb immediately.
Obtain workshop assistance if
necessary.
Defective switch
low beam
12
Flashes red
Flashes red
Driver's display
Symbol
Text message
Malfunction
gearbox ECU
Limp-home brake
control unit
Trailer brake
Tractor ABS
Trailer ABS
Retarder temperature
too high
Check lamps
Yellow
Red
Red
Red
Red
Red
Yellow
Yellow
Yellow
Yellow
Flashes red
Retarder temperature
too high
Retarder power
reduced
Red
Check fuse.
Primary retarder:
Retarder has failed.
Red
Yellow
Procedure
Malfunction
sust.-action brake
Malfunction
ESP
Meaning
Check fuses.
Check fuse.
13
Driver's display
Symbol
Text message
Checklamps
Meaning
Procedure
Malfunction
air suspension
Red
Charge voltage
too low
Oil pressure
too low
Flashes
red
Red
14
Red
Red
Red
Yellow
Yellow
Yellow
Red
Top up coolant.
Top up oil.
Yellow
Coolant level
too low
Change
air filter
Red
Yellow
Check engine
oil level
Coolant temperature
too high
Red
Driver's display
Symbol
Text message
Gearbox temperature
too high
Air pressure
DO NOT SHIFT
Gearbox temperature
too high
Check lamps
Meaning
Flashes red
Red
Red
Red
Yellow
Yellow
Red
Lock liftgate
Flashes
red
Red
Yellow
Yellow
Check fuse.
Check fuse.
Check fuse.
Flashes
red
Yellow
Tipper operation
Yellow
Procedure
Failure of a left-hand/right-hand
tractor indicator.
15
Driver's display
Symbol
Text message
Check lamps
Track/trailer brake
lamp failure
Red
Tachograph
malfunction
Check tachograph
Malfunction
tyre pressure mon.
Tyre defective
Tyres
Tyre pressure
too low/high
Trailer tyres
16
Procedure
Check fuse.
Check fuse.
Check fuse.
Red
EU monitoring device
(tachograph) has failed.
Red
EU monitoring device
(tachograph) is not OK.
Yellow
Yellow
Yellow
Yellow
Yellow
Check
tyre pressure
Meaning
Yellow
Yellow
Yellow
Yellow
Yellow
Driver's display
Symbol
Text message
Circ. 1, 2, 3, 4
pressure
too low
Circ. 1, 2, 3, 4
pressure
PSC failure
CAN interconnect
failure
ZBR failure
FFR failure
EDC failure
EDC S failure
Cooling system
Stop engine
TCU failure
Check lamps
Flashes
red
Flashes
red
Flashes
red
Meaning
Red
Red
Red
Red
Flashes
red
Yellow
Yellow
Connection between
instrument panel and central
electrical system has failed
Flashes red
Flashes red
Flashes red
Flashes red
Flashes red
Flashes red
Procedure
EDC S failed
17
Driver's display
Symbol
Text message
Check lamps
Flashes red
Defective switch
haz.warn. lights
Flashes red
Change bulb.
Otherwise tow.
Deactivate retarder.
Red
Yellow
WSK
failure
Red
Yellow
EBS
emergency prog.
Red
Red
Red
Red
Trailer brake
Trailer brake
temperature
Tractor ABS
failure
Trailer ABS
Retarder temperature
too high
Retarder temperature
too high
18
Procedure
Trailing/leading axle
failure
Defective switch
low beam
Meaning
Yellow
Yellow
Yellow
Yellow
Yellow
Flashes red
Deactivate retarder.
Driver's display
Symbol
Text message
Check lamps
RET P
failure
Battery
undervoltage
Oil pressure
too low
Oil pressure
too high
Red
Retarder power
reduced
ECAS
failure
Red
RET S
failure
ESP
failure
Meaning
Red/
yellow
Yellow
Red
Red
ESP failed
Procedure
Battery undervoltage
Yellow
Flashes
red
Red
Flashes
red
Red
Red
Yellow
Flashes red
19
Driver's display
Symbol
Text message
Check lamps
Top up coolant.
Stop.
Tow.
Lock liftgate.
Change bulb.
Yellow
Check fuse.
Change bulb.
Yellow
Check fuse.
Change LED block
Yellow
Check fuse.
Change bulb.
Check fuse.
Change bulb.
Check fuse.
Check fuse.
Yellow
Yellow
Yellow
Red
Flashes red
Red
Yellow
Air pressure
DO NOT SHIFT
Gearbox temperature
too high
Steer oil press.
too low
Steering oil
level fault
Red
Yellow
Tipper operation
Flashes
red
Red
Lock liftgate
Flashes
red
Red
Red
Tractor brake
lampfailure
Red
Check TCO
20
Red
Procedure
Coolant temperature
too high
Change
air filter
Meaning
Red
Driver's display
Symbol
Text message
Meaning
Procedure
Red
Check fuse.
Tyre
defective
Stop.
Yellow
Check
tyres
Stop.
Yellow
TPM
failure
Check lamps
Check
tyre pressure
Yellow
Tyre pressure
too low
Yellow
Tyre pressure
too high
Yellow
Check
trailer tyres
Yellow
21
Notes
Danger!
Warning!
acid!
protection.
vent holes.
battery manufacturer.
22
2.2.3
Connecting terminals
a
2
5
b
23
24
Warning!
Danger of fatal injury if the vehicle rolls away
uncontrollably! Depending on the damage status,
the vehicle could start moving uncontrollably when
the driveline is disconnected.
Caution!
Danger of gearbox damage! During towing,
adequate lubrication of the gearbox is not
guaranteed.
Sticker on the cab: The cross indicates that the driveline must be
disconnected before towing
25
Installation positions
3.2.2
flanges(6).
disconnected.
After towing
26
Installation positions
3.3.2
Special tool
3.3.3
Preparations
27
Hypoid axles have a single axle ratio; they are used above
all in on-road vehicles.
Current series (with grease lubrication of the axles):
2
1
28
Remove the hypoid axle shaft (example shows the older series with oil
lubrication)
Planetary final drive axles are axles with double ratios; they
are used in construction vehicles, for example.
or
Refill the oil which drained out. Use an oil filler tank for
this purpose.
5
1
29
30
Notes
Warning!
This brief overview only offers you an overview of
the main controls and functions of the vehicle.
However, it by no means replaces the operator's
manual with the important explanations and safety
notes contained therein.
17
9
16
15
14
13
12
11
10
equipment.
Refer to chapter 2.1 for important information
about indications on the display andcheck
lamps.
4.1.2
Instrument panel
Instrument panel
1 Rev counter
2 Display of outdoor temperature, black ice warning, total
mileage
3 Display
4 Check lamps
5 Sensor for automatic brightness control of the
instrument lighting, display of the EU monitoring device,
keys of the multifunction steering wheel (if fitted)
6 Speedometer
7 Display of time, trip counter, speed in mph
8 Warning speed
9 Reservoir pressure
10 Operate Vehicle menu, confirm yellow messages on the
display, km/h or mph display
11 Calling up and using the Vehicle menu
12 Reservoir pressure in brake circuit I
13 Differential locks
14 Coolant temperature
15 Select language of the display, set instrument lighting
16 Changeover between fuel and AdBlue level
17 Fuel level, reduction agent level (AdBlue)
31
Display
Press key(4).
selected.
1
2
3
32
2 Adjust armrests
3 Adjust backrest angle
4 Adjust height of seat base
5 Adjust vertical damper (soft/hard)
3
7
10
13
11
14
12
15
20
Adjusting the steering wheel
There must be sufficient reservoir pressure in the
compressed air system in order to adjust the steering
wheel.
First set the drivers seat, then adapt the steering wheel
19
18
17
16
15
21
33
4.1.4
10
11
12
13
16
15
8 Set blower
9 Cooling with the engine running
10 Set the temperature
11 Display
12 Ventilating the side windows
13 De-humidify the incoming air
14 Adjust air distribution
16 Change over between fresh air and recirculating air
19
18
17
34
14
4.1.5
Braking
released position.
The check lamp goes out
Activating the engine brake
Retarder/Intarder
Increasing braking power gradually:
Switching off:
35
MAN BrakeMatic
1
2
Switching off BrakeMatic
#,
1
1,
4.1.6
Gearbox operation
D
Manoeuvre, forwards:
DM
Neutral:
Drive, reverse:
Manoeuvre, reverse:
RM
Note
%%
7.
, -
,$,
Press key(4).
Upshift:
.%%
, -
43.
43.
.%
, 7
2$3
3
Steering column switch in vehicles
without multifunctional steering
wheel
Downshift:
36
Gearbox
1 Toggle switch (range-change group)
3
2
1
Shift lever
5 High range
6 Engaged gear
"N": Neutral
"R": Reverse
"": No gear engaged)
7 Splitter group high
8 Splitter group low
37
frame is lowered!
3
2
1
Press keys (7) and (5) again to switch off ECAS remote
control.
9
10
3
Ignition lock
Ignition key positions:
Only in vehicles with a flame start system: "flame start" check lamp
on the display
39
Notes
Warning!
This brief overview only offers you an overview of
the main controls and functions of the vehicle.
1
15
14
13
12
11
10
Instrument panel (Highline version; Baseline with small display area (5) and
additional panel of check lamps)
4.2.2
16
Instrument panel
Instrument panel
1 Hazard warning light
2 Fog lights and rear fog light
17
40
11
10
Instrument panel (Highline version; Baseline with small display area (5) and
additional panel of check lamps)
Highline:
16
Press to confirm
17
Display
41
10
18
17
16
15
9 Light test
10 Headlight beam regulator
11 Pressure indicator in brake circuit II
12 Operate Vehicle menu, confirm yellow messages on the
display, km/h or mph display
13 Calling up and using the Vehicle menu
14 Pressure indicator in brake circuit I
15 Coolant temperature
16 Instrument lighting
17 Time, outside temperature changeover switch
18 Check the fuel
42
14
13
12
11
13
12
Display
Press key(17).
14
15
16
17
43
2
3
First set the drivers seat, then adapt the steering wheel
to the modified seat position.
44
1
Adjusting the mirrors
1 Select side (left/right side)
5
3 Select mirror:
4.2.4
10
11
12
7 Dehumidification on/off
8 Air conditioner on/off
9 Heating temperature selection
10 Fresh air/recirculating air
11 Blower
12 Selection of nozzles
45
Braking
Retarder/Intarder
Switching off:
46
MAN BrakeMatic
1
2
Switching off BrakeMatic
1
#
#,
4.2.6
#
1,
Gearbox operation
D1 and D3 or D
(depending on version of the
DNR switch)
Manoeuvre, forwards:
DM
Neutral:
Drive, reverse:
R1
Manoeuvre, reverse:
RM
4
,
Note
Press key(4).
Upshift:
, -
,$,
%%
7.
.%%
, -
43.
43.
.%
, 7
2$3
3
Steering column switch in vehicles
without multifunctional steering
wheel
Display: "Automatic"
Downshift:
47
Gearbox
1 Toggle switch
down: Gears 1 4 and reverse
up: Gears 5 8
2 Slide switch
3
2
1
Shift lever
4 Neutral position
5 Engaged gear
6 Gears 14 (low range)
48
frame is lowered!
3
2
9
10
3
Ignition lock
Ignition key positions:
50
Only in vehicles with a flame start system: "flame start" check lamp on the
display
Safety instructions
Danger!
Caution!
the entry steps and the tyres when both the air
horizontal position.
Caution!
is being tilted.
position.
Warning!
The function of a pacemaker can be
severely impaired due to the EM radiation
Caution!
Note
compartment.
51
3
2
Reversing valve
Stow away the tool kit, close the front flap (TGX, TGS)
and close the cover in the entry.
After tilting:
Check the locks see next page
52
Press button (4) until the cab has reached the end
position
failed.
Lowering the cab electrically
cab locks.
You will hear the pump motor running heavily after the
Close the front flap (TGX, TGS), close the cover in the
entry and press the top of the rocker button.
After tilting:
Before the truck is driven, the lever of the changeover
valve must always be moved down, as far as the stop.
The "cab lock" and "central warning light" check lamps
Reversing valve
must go out.
Also, the "STOP" symbol with the "LOCK CAB"
message must go out on the driver's display.
53
Dipstick
Caution!
Too much oil is damaging for the engine and the
environment!
Checking coolant
The vehicle must be on a level surface for checking the
coolant level.
with the front flap open and the engine cold, look at the
viewing window (3) (level not below the middle of the
viewing window).
Oil filler pipe and expansion tank for coolant
Topping up coolant
Warning!
Danger of injury! The cooling system is under pressure and at a high temperature.
Caution!
Excessive temperature differentials can damage the
engine!
54
If the level is too low, top up the fluid to the correct level
through the filler hole (3).
55
4.3.4
Changing a wheel
Safety instructions
Pump tappet
Danger!
Inadequate support can allow the vehicle to move
Jacking points
Warning!
Other vehicles represent a sustained and
increased risk of accidents at the breakdown site!
Warning!
On all vehicles with air suspension: Adjustment of
the electronically controlled air suspension (ECAS)
can cause the jack to slip!
56
Jacking points
57
Changing a wheel
58
Tow-starting
Safety instructions
Warning!
Caution!
Tow-starting
Warning!
There is no steering support if the engine is
stopped! Considerable effort is required at the
steering wheel.
reached.
Stop.
engaged.
59
Notes
Safety instructions
Warning!
Caution!
towed combination.
drive:
broken-down vehicle.
see chapter 3.
functional:
60
see chapter 3.
does not have any contact with the ground during towing.
accumulators mechanically.
61
9RUUDWVGUXFN
]XJHULQJ
Safety instructions
Warning!
following chapters:
Warning!
vehicle is functioning:
cylinder.
62
7.5bar
Maximum pressure:
12.5bar
filler connection.
9RUUDWVGUXFN
]XJHULQJ
Note
If the vehicle is towed when raised:
towing as well.
4
63
Warning!
Danger of injury due to trapping!
Caution!
effect is cancelled.
Release torque of the release spindle: max. 35Nm
The parking brake is now released and does not function.
The check lamps and warning lights on the instrument
panel remain lit.
In three and four-axle vehicles with air suspension:
Indicator (2) projects from the spring-loaded accumulator
housing.
64
Inoperative spring-loaded brake cylinder NG3 with indicator sticking out (in
air-sprung three-axle and four-axle vehicle)
PD[
PP
65
Caution!
Danger of accidents!
below.
Warning!
Caution!
Towing the vehicle when loading can cause
additional damage!
66
Towing bar:
A towing bar between the two towing eyes ensures a
stable connection and even force application. MAN offers
a shunting coupling developed specially for all heavyrange vehicles (parts no. 81.42015.6028, see also
appendix6.1).
67
Towing:
Precondition: The driveline is disconnected
( see chapter3).
After towing:
2
3
1
4
68
Steel bumper and tow bar hitch (e.g.: TGS; TGX and TGA similar
Towing:
Precondition: The driveline is disconnected
( see chapter3).
2
3
1
4
69
Warning!
additional damage!
eye.
70
Vehicle concept
++ = Only possibility
Laden
vehicle
+ = Preferred method
no
no
yes
no
yes
+ +2)
no
yes
= Possible
= Unfavourable
= Not permitted
1) Only in vehicles with plastic bumpers. Lifting at the tow bar hitch is not permitted.
2) Remove the front wheels, 2nd front axle must also carry the load
71
72
When lifting, make sure that both towing eyes are evenly
loaded. If necessary, lower the underbody lift, unhook it
and hook it back in.
Make sure that the rear end does not touch the ground
when driving, even when the ground is uneven. If
possible, raise the vehicle to its highest position with air
suspension.
73
Note
Lifting the vehicle at the front wheels is described
here with the example of a wheel lift unit. Proficient
use of wheel grippers is also possible and
Towing a tipper with the front wheels lifted using a wheel lift unit
permitted.
Requirements:
Driveline is disconnected ( see chapter 3).
Preparatory work on vehicles with reduced ground
clearance:
chains.
74
Four-axle vehicles:
If the vehicle is laden: Lift the vehicle with axle forks, the
second front axle must also carry the load.
Further information on page 78 must be complied with.
Both front axles have no contact with the ground; only permitted if the
vehicle is unladen
longitudinal links!
75
Preconditions:
Driveline is disconnected ( see chapter3)
Preliminary work if the ground clearance is inadequate:
Towing a vehicle with air suspension, lifted at the front with axle forks (e.g.:
TGX)
Four-axle vehicles:
Hooking axle forks onto the front axle and securing with chains
76
Preconditions:
Driveline is disconnected ( see chapter 3).
Preliminary work if the ground clearance is inadequate:
Four-axle vehicles:
Hooking axle forks onto the front axle and securing with chains
77
Clamp the first front axle onto the axle beam of the
second front axle (3). This distributes the pulling forces
between both axles.
supports the load. This takes the load off the chassis
frame.
Clamping front axles (note: The vehicle has been lifted more than usual for
the purpose of the photo)
Towing when lifted with the front wheels removed, the second front axle
also carries the load
78
Warning!
If the front axle is not secured, it could become
involved in the steering procedure and cause a
serious traffic accident!
Warning!
Dangers of accidents due to inadequate brake
force and malfunctions of the ABS and ASR!
79
Caution!
Lifting and towing a laden vehicle can cause
additional damage!
Caution!
Danger of severe damage to the frame in four-axle
vehicles! The ladder frame structure at the front
is not designed for the fifth-wheel steering loads
that occur in four-axle vehicles or trucks with two
steered front axles.
Note
There is no need to disconnect the driveline when
towing with the rear lifted, as long as the front axle
is not driven.
80
Preliminary work:
Cross head attached to the rear crossmember using axle forks and chains
Lift vehicles with several rear axles until all rear wheels
no longer have contact with the ground.
Note
Comply with the permitted axle load.
81
Note
Lifting the vehicle at the rear wheels is described
here taking the example of wheel grippers.
Correct use of a wheel lift unit is also possible and
permitted.
Preliminary work:
Lift vehicles with rear axles until all rear wheels are no
longer in contact with the ground.
82
Lifting a vehicle with a double rear-axle assembly until the rear wheels are
not longer in contact with the ground
Preliminary work:
Towing a three-axle vehicle with air suspension, lifted at the rear wheels
Tie the front rear axle onto the frame using straps
Tying up the front axle (note: the vehicle has been lifted for the photograph;
only tie up the axle if the vehicle is lowered)
valves.
Lift vehicles with two rear axles until all rear wheels are
no longer in contact with the ground.
83
Move the underbody lift under the vehicle and hook the
axle forks onto the rear axle beam.
Lift vehicles with two rear axles until all rear wheels are
no longer in contact with the ground.
84
Removing the anti-roll bar before lifting with the axle forks
Notes
The pneumatic brake systems of both vehicles are
connected together for automatic combined braking. In
order to ensure there is an adequate reservoir pressure
in the towed vehicle during towing, compressed air is
additionally supplied.
Warning!
Danger of accident if the brake force in the towed
vehicle is too high or too low! Depending on the
loading status and condition of the road, the brake
force transmitted from the towing vehicle may be
too high or too low.
85
Warning!
Danger of injury by compressed air! The pedal
brake valve is under high pressure when the brake
pedal in the cab is pressed.
Release the lock in the cab and open the front flap.
Warning!
Danger of accidents due to unbraked trailer!
86
Filling connections:
At the test connections, under the battery box; the filling
connection (1) is identified with "IN"
or
filler connection.
After towing
Warning!
Significant risk of accidents if the brake system if
faulty!
87
Notes
high speed.
88
Reducing loadings
In an emergency or
if unloading is not technically feasible (e.g. cement
mixer) or
inadvisable (e.g. refrigerated vehicle)
)*
)6
)6
3
Wrong: Pulling straps form an obtuse angle. The resulting cable forces FS
are significantly greater than the weight FG of the lifted vehicle. In addition,
concentrating forces at "P" leads to instability.
89
)
)
) )
)
)!)
90
Correct:
When pulling straight ahead, the
pulling force is no greater than
absolutely necessary.
Wrong:
The angled pull means that too
much pulling force has to be
applied.
91
92
Force application via MAN shunting coupling and two towing eyes
Rear crossmember
Application:
In all vehicles
93
Force application points in the area of the leaf-spring front axle (example shows one-leaf spring; similar for two and three-leaf springs)
94
Force application points in the area of the air-sprung front axle (one-leaf spring)
95
Force application points in the area of the leaf-sprung rear axle (example shows two-leaf spring; similar with other numbers of leaves)
96
97
Force application points at the rear on an air-sprung rear axle with X-link
98
Wheel hubs
Application:
Suitable force application systems are required in all
vehicles; reference addresses see appendix 6.1.
Function:
Force application via wheel hub clamps on all wheels
For lifting the entire vehicle with one or two mobile
cranes
Force application on the rear axle of the tractor vehicle (middle right) and on
the semitrailer rear axles (bottom right)
99
Recommendation:
100
Preliminary work:
4.5.5
Righting:
After righting:
Caution!
Danger of engine damage oil knock!
4.5.7
102
5.1.1
Notes
Warning!
This quick reference guide offers you simply an
overview of important controls and functions of
the vehicle. It does not replace the operator's
17
9
16
15
14
13
12
11
10
equipment.
Refer to chapter 2.1 for important information
about indications on the display andcheck
lamps.
5.1.2
Dashboard
Display
Press key(4).
selected.
1
2
3
104
2 Adjust armrests
3 Adjust backrest angle
4 Adjust height of seat base
First set the drivers seat, then adapt the steering wheel
11
10
13
14
12
15
Door module
105
5.1.4
5.1.5
Braking
10
11
.-
.%
.%%
,
43.
6(7
MAN BrakeMatic
BrakeMatic is switched on automatically after the ignition is
switched on. No check lamp in rocker button (12) comes
on.
Switch off BrakeMatic
12
13
BrakeMatic toggle switch
Display showing BrakeMatic and
cruise control switched on
Gearbox operation
#,
D
Manoeuvre, forwards:
DM
Neutral:
Drive, reverse:
Manoeuvre, reverse:
RM
1
1,
Note
Press key(2).
handle(4).
.%
.-
Upshift:
,$,
, -
43.
Downshift:
.%%
2$3
107
frame is lowered!
3
2
1
Press keys (7) and (5) again to switch off ECAS remote
control.
9
10
3
Ignition lock
Ignition key positions:
Only in vehicles with a flame start system: "Flame start" check lamp on the
display
109
Safety instructions
Danger!
Caution!
horizontal position.
Caution!
tilting process.
cab.
being tilted.
Warning!
The function of a pacemaker can be severely
impaired due to the EM radiation from the engine
control unit!
110
The changeover valve for tilting the cab is fitted behind the
rear wall of the cab.
position
The cab suddenly drops into the cab lock over the
last 10 to 15cm!
Changeover valve cab C
Danger!
If the cab is not locked, it can tilt forwards on
braking and cause serious accidents!
After tilting
111
Oil temperature
Waiting time
0C
90min
20C
45min
50C
5min
80C
4min
110C
3min
or
With the front flap open, check using the dipstick (1).
Checking coolant
The vehicle must be on a level surface for checking the
coolant level.
Topping up coolant
1
Warning!
The cooling system is under pressure and at high
temperature!
Caution!
Topping up coolant
If the level is too low, top up the fluid to the correct level
through the filler hole (2).
Dipstick
113
If the level is too low, top up the fluid to the correct level
through the filler hole (2).
5.2.3
114
Pump tappet
Changing a wheel
Danger!
Inadequate support can allow the vehicle to move
downwards uncontrollably and cause severe
injuries!
Warning!
Other vehicles represent a sustained and
increased risk of accidents at the breakdown site!
Warning!
On all vehicles with air suspension: The jack
may slip out of position due to regulation of the
electronically controlled air suspension.
115
Jacking points
116
Tow-starting
Safety instructions
Warning!
Caution!
Tow-starting
chapter5.3.2.
Warning!
or
reached.
5.3.3.
Stop.
In 9-speed gearboxes:
most.
117
Notes
Safety instructions
Warning!
entire combination.
broken-down vehicle.
braking:
the vehicle.
not functioning:
does not have any contact with the ground during towing.
see chapter 3.
If the damaged axle cannot be lifted during towing:
For versions 4x4:
see chapter 3.
118
9RUUDWVGUXFN
]XJHULQJ
Safety instructions
Warning!
Danger of a serious traffic accident due to lack of
chapters:
Warning!
page.
119
7.5bar
Maximum pressure:
12.5bar
filler connection.
9RUUDWVGUXFN
]XJHULQJ
120
Warning!
Danger of injury due to trapping!
Caution!
Inoperative spring-loaded brake cylinder NG3 with indicator sticking out (in
air-sprung three-axle and four-axle vehicle)
121
PD[
PP
122
Caution!
Danger of accidents!
Only use the tow bar hitch for pulling, never for
lifting the vehicle.
Warning!
and at an angle.
Caution!
additional damage!
123
see chapter 3.
Towing
steering lock.
possible.
3
1
124
Warning!
Danger of accidents due to inadequate braking
effort!
Caution!
Lifting and towing a laden vehicle can cause
additional damage!
125
Note
Lifting the vehicle at the front wheels is described
here with the example of a wheel lift unit. Correct
Move the wheel lift unit under the vehicle and set it to
the track width of the vehicle.
Make sure that the rear end does not touch the ground
when driving, even when the ground is uneven. If
Also make sure there is adequate distance between the front axle and
cross head at the front
126
Preconditions:
In order to get axle forks under the front axle, it is necessary for the vehicle
to be on blocks or ramps
Move the underbody lift under the vehicle and hook the
axle forks onto the front axle.
Hooking axle forks onto the air-sprung front axle and securing with chains
127
Make sure that the rear end does not touch the ground
128
Warning!
effort!
Caution!
axles.
additional damage!
Note
Warning!
The unsecured front axle can cause a severe
traffic accident due to uncontrolled steering!
Warning!
Dangers of accidents due to malfunctions of ABS
and ASR!
129
Note
Lifting the vehicle at the rear wheels is described
here taking example of wheel grippers. Correct
Lift vehicles with two rear axles until all rear wheels are
no longer in contact with the ground.
2
Make sure there is sufficient distance between the air bellows carrier and
cross head of the underbody lift
130
Preliminary work:
In order to get axle forks under the axle, it is necessary for the vehicle to be
on ramps
Hooking axle forks onto the air-sprung rear axle and securing with chains
131
or
132
Notes
Warning!
vehicle.
carefully.
133
filler connection.
After towing
Warning!
Significant risk of accidents if the brake system is
faulty!
134
Notes
135
In an emergency or
if unloading is not technically feasible or
inadvisable (e.g. refrigerated vehicle)
)
)
Reducing loadings
) )
)
)!)
136
Correct:
When pulling straight ahead, the
pulling force is no greater than
absolutely necessary.
Wrong:
The angled pull means that too
much pulling force has to be
applied.
137
Rear crossmember
Wheel hubs
the frame
138
components.
Underride guard
Built-on parts
Axle guidance components
Tubular crossmember
139
appendix6.3.
Note
Fold up the front grille and fold down the number plate
carrier.
Pull the cotter pin (2) out of the pin (3), pull the pin out
of the tow bar hitch.
5
Disconnecting electrical connections and hoses
140
When fitting the towing equipment, watch out for electric cables and
hydraulic lines
an angle.
5.4.5
cross member.
141
Righting:
After righting:
Caution!
Danger of engine damage oil knock!
5.4.7
142
143
144
6 Appendix
6.1 Tools and materials
6.1.1
Reference sources
MAN parts no.
Others
Designation
Purpose
Octagonal socket
80.99603.0261
80.99613.0027
80.99629.0011
08.04046.9000
Support handle
80.99617.0005
Stud bolt
06.06138.0712
Dummy cover
for 17.5, 19.5 and 22.5 tyres
6.1.2
Do-it-yourself.
E.g. remove the wheel
covers from an axle
shaft that has been
taken out of service.
Reference sources
MAN parts no.
Others
Designation
Purpose
Prolux-System-technik
E.g. Prolux-Systemtechnik
145
6 Appendix
6.1 Tools and and equipment
6.1.3
Designation
Purpose
Towing lug
81.42015.6025
Shunting coupling
81.42015.6028
Thread cleaner
08.42914.0509
80.99619-0067
81.9302121-0089
6.1.4
Series TGL/TGM
Reference sources
MAN parts no.
Others
Designation
Purpose
19 mm spanner
6.1.5
08.06003.9000
Prolux-Systemtechnik GmbH&Co KG
Bahnhofstrae 60
Am Schinderwasen 7
D-76865 Rohrbach/Pfalz
D-89134 Blaustein
Krause GmbH
Bsmann GmbH
Dr. Berns-Strae 10
Lange Strae 46
D-47441 Moers
D-27412 Blstedt
146
6 Appendix
6.2 Safety components
6.2.1
6.2.2
Wheel
Steering axle
Rear axle
Rear axle tube, axle beam
Propshaft
Cab
Cab mounting
Four-point link/X-link
147
6 Appendix
6.3 Maximum permitted pulling force
6.3.1
TGA series
Maximum permitted pulling force
Pulling straight ahead
Pulling at an angle
Attachment point
Individual towing eye
200k N (20t)
100k N (10t)
330k N (33t)
200k N (20t)
400k N (40t)
200k N (20t)
6.3.2
Attachment point
Individual towing eye:
4x2/6x2, leaf suspension on FA
140k N (14t)
90k N (9t)
Other vehicles
250k N (25t)
160k N (16t)
Coupling jaw:
Light four-axle vehicle, 4x2/6x2
175k N (17.5t)
110k N (11t)
Other vehicles
320k N (32t)
210k N (21t)
280k N (28t)
180k N (18t)
Other vehicles
400k N (40t)
300k N (30t)
Shackle (each)
100k N (10t)
100k N (10t)
6.3.3
Attachment point
Coupling jaw:
Tonnages 7.5t to 10t
50k N (5t)
30k N (3t)
130k N (13t)
80k N (8t)
75k N (7.5t)
50k N (5t)
190k N (19t)
120k N (12t)
50k N (5t)
50k N (5t)
Shackle (each)
148
6 Appendix
6.4 Index
A
AdBlue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ECAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
F
Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Filling connections . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 87
Force application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Brands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51, 110, 147
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Checking the engine oil . . . . . . . . . . . . . . . . . . . . . . 54, 112
Check lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ComfortShift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 48
HydroDrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7, 26, 61
I
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Differential box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27, 145
149
6 Appendix
6.4 Index
J
Pump tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Leaf-sprung vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Retarder/Intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 46
Righting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 142
Righting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . 101, 142
Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Model plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ServoShift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37, 48
Setting the ride height . . . . . . . . . . . . . . . . . . . . 38, 49, 108
Shunting coupling . . . . . . . . . . . . . . . . . . . . . . . 67, 92, 100
external source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Technical status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
150
6 Appendix
6.4 Index
Test connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Tightening torques for wheel nuts . . . . . . . . . . . . . . 58, 116
Tilting the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51, 110
TipMatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 47, 107
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145146
Tow bar . . . . . . . . . . . 59, 60, 6667, 69, 117119, 123124
Tow bar hitch . . . . . . . . . . . . . . . . . . . . . . 69, 93, 100, 123
Towing bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Towing eyes . . . . . . . . . . . 4, 67, 70, 72, 74, 7677, 92, 100
Towing with the front of the vehicle lifted . . . . . . 70, 71, 125
Tow-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 117
TPM tyre pressure monitoring . . . . . . . . . . . . . . . . . . . . . 58
Trailing axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Transfer case damage . . . . . . . . . . . . . . . . . . . . 25, 60, 118
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tubular crossmember . . . . . . . . . . . . . . . . . . . . . . . 91, 139
U
Underbody lift . . . . . . . . . . . 72, 76, 77, 81, 84, 102, 127, 142
Underride guard . . . . . . . . . . . . . . . . . . . . . . . . . . . 91, 139
Using the menu . . . . . . . . . . . . . . . . . . . . . 32, 41, 43, 104
V
Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . 5
Vehicle number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
W
Wheel formulae . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Wheel gripper . . . . . . . . . . . . . . . . . . . . . . . 74, 82, 126, 130
Wheel hub clamp . . . . . . . . . . . . . . . . . . . . . . . . . . 99, 142
Wheel hubs . . . . . . . . . . . . . . . . . . . . . . . . . . 99, 102, 138
Wheel lift unit . . . . . . . . . . . . . . . . . . . . . . . . . . 74, 82, 126
Wheel modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
X
X-link (four-point link) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
151
Notes
152
Editorial
We are delighted to present you our handbook
entitled "Trucknology mobile Breakdown
Assistance I Recovery I Towing".
It is intended to be used as a working manual, a
training document and a reference work for towing
and breakdown services, motor vehicle service
workshops and other interested vehicle operators.
Our experts from technology and sales hope that this
will provide you with a clear explanation of the evergrowing basic knowledge required to keep TGX, TGS,
TGA, TGM and TGL vehicles mobile even in the event
of damage. Also, it should provide information about
the correct procedures for removing these vehicles
from a possible accident location.
The recommendations for towing and recovery
measures assume that the personnel involved
have the necessary professional qualification and
knowledge of the regulations.
Publisher:
MANTruck&BusAG
Dachauer Strasse 667
D-80995 Mnchen
After Sales Documentation
Markus Jaser
Tel. +49 89 1580-3148
markus.jaser@man.eu
Central Testing Department
Jrg Friedrich
Tel. +49 89 1580-1418
joerg.friedrich@man.eu
MANTruck&BusAG
Postfach 50 06 20
D-80976 Mnchen
www.mantruckandbus.com
A MAN Group company
T rucknology mobile.
M
anual of Breakdown Assistance I Recovery I
Towing.