Recovery PDF

D 81.
99185-1052 mu 12/11 Printed in Germany

The information in text and illustrations is non-binding.
Subject to modifications in response to technical progress. T rucknology mobile.
anual of Breakdown Assistance I Recovery I
M
MANTruck&BusAG
Towing.
Postfach 50 06 20
D-80976 Mnchen
www.mantruckandbus.com
A MAN Group company
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 ever-
growing 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
Agency performing the work: Thewald Kommunikation

2011 MAN Truck & Bus AG
Information about recovery procedures is
intended for specialist companies; these
procedures are always subject to the
judgement of the person(s) carrying out
the work, and presuppose that the relevant
experience has been gained.
Due to the highly complex nature of this
field, MAN refuses to accept any warranty
claims or claims for damages attributable to
the vehicle recovery process.
In any event, recovery and towing measures
must be followed by a technical inspection at
the nearest MAN Service Centre, for reasons
of safety. You can find an overview of MAN
branches at: w ww.mantruckandbus.com
Wishing you every success,
MANTruck&BusAG
I
Overview and business units
Overview
Pioneering spirit has always been the driving force behind MAN engineers for Brands
more than a century. The ground-breaking and ingenious invention by Rudolf
Diesel achieved between 1893 and 1897 at MAN proved to be a powerful engine
of progress: the diesel engine.
Not only did it replace the steam engines which were in normal use at the time, it
also fired the starting pistol and set the trend for the construction of commercial
(Trucks, buses)
vehicles.
Even today, technological leadership in commercial vehicles remains an
important element of our company strategy. Innovative transport solutions for all
of tomorrow's requirements that is the goal of MAN.
Self-image (VIP class buses)
As an international supplier of trucks, buses, coaches, engines and components,

MAN possesses a clear strategic vision: to be a leading supplier of commercial
vehicles. The employees at MAN contribute their expertise to this day-in,
day-out. They produce products and offer services which contribute to the
success of MAN customers all over the world.
Product description (Trucks, bus chassis)
One of the leading suppliers of trucks, buses, coaches and corresponding

services in Europe
Production and cooperation sites all over the world
MAN Latin America is the market leader in South America for trucks in
excess of 3.5t.
Joint ventures such as those with the Indian commercial vehicle
manufacturer, Force, and the Chinese truck manufacturer Sinotruk
Production and manufacturing sites in Germany, Austria, Poland, Russia, (Heavy trucks, China)
Turkey, South Africa, Brazil and India
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
Service contracts with differentiated levels of service for maintenance

and repairs
Breakdown assistance, cashless payment management
TeleMatics, ProfiDrive (driving training), communication on board, fleet

management
Financing, leasing, full service (CombiContract), insurance
Vehicles in all categories, semitrailers, trailers for all transport functions

Flexible rental times, full-service rental
Used vehicles (trucks, buses, coaches) of all brands and categories
III
MAN sites worldwide
Present in global markets
MAN sales regions and production sites
Sales regions
Vertriebsregionen
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Germany
Munich (heavy trucks, cabs, driven axles) Plauen (premium coaches, double-deckers)
Nuremberg (engines) Salzgitter (heavy trucks, bus chassis, components)
IV
Austria Brazil (MAN Latin America)
Steyr (light/medium trucks, cabs) Resende (heavy, medium and light trucks, bus chassis)
Vienna (special vehicles)
Poland South Africa

Krakow (heavy trucks) Olifantsfontein (inter-city and line service buses)
Poznan (inner-city buses, bus chassis) Pinetown (heavy, medium and light trucks, bus chassis)
Starachowice (body-in-white for buses)
Turkey Mexico India (MAN FORCE China (Sinotruk Ltd.)

Ankara (coaches, inter- Quertaro (trucks and TRUCKS) Jinan (heavy trucks)
city and line service buses) Pithampur (heavy trucks)
buses)
V
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 Presentation of the new VIP class coach NEOPLAN Skyliner MAN
TGX 18.400 "Green Truck 2011"
2010 MAN Lion's City (hybrid inner-city bus) enters series production
2008 Intercooling based on the low-temperature concept MAN TGX/TGS
series: "Truck of the Year" for the 7th time
2007 Launch of the MAN TGX V8 the most powerful series production
truck in Europe
2006 "Coach of the Year" for the Starliner
2006 "Truck of the Year" award for the TGL medium series
2005 L aunch of the Trucknology generation for the light and medium
series: TGL, TGM
2004 D20 CommonRail launch
2003 Lion's Star coach: "Coach of the Year"
2002 Lion's Star coach: "reddot award: product design"
2001 Takeover of NEOPLAN Bus GmbH
2001 Takeover of ERF Ltd., UK
2001 TGA heavy goods vehicle: "Truck of the Year"
2000 Launch of the Trucknology generation: TGA
1999 Takeover of STAR TRUCKS, Poland
1999 Low-floor regular-service bus: "Bus of the Year"
1995 "Truck of the Year" for the fourth time with the F2000
1994 Lion's Star coach is awarded "Coach of the Year"
1993 Launch of the L 2000 light range
1990 Takeover of Steyr Nutzfahrzeuge AG
1987 "Truck of the Year" award for the F90 series
1980 "Truck of the Year" award for the 19.321, type F8
1979 Use of intercooling with the turbo diesel
1978 "Truck of the Year" award for the 19.280, type F8
1971 Takeover of Bssing-Automobilwerke
1955 Foundation of the MAN plant in Munich
1951 First German truck diesel engine with exhaust turbocharging
1924 Trucks and buses driven by diesel engines with direct injection
1923 First direct injection for vehicle diesel engines ready for the market
1915 First MAN truck
1897 First diesel engine developed and built at MAN
VI
VII
Contents
1 General information . . . . . . . . . . . . . . . . . . 3 4 TGX, TGS and TGA series . . . . . . . . . . . . . 31
1.1 About this handbook . . . . . . . . . . . . . . . . . . . . . 3 4.1 Quick reference guide for TGX, TGS . . . . . . . . 31
1.1.1 Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4.1.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.1.2 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4.1.2 Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.1.3 Technical status . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4.1.3 Adjusting the seat, steering wheel and mirrors . . 33
1.1.4 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4.1.4 Heating, ventilation and air conditioning . . . . . . . 34
4.1.5 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 Vehicle identification . . . . . . . . . . . . . . . . . . . . . 4 4.1.6 Gearbox operation . . . . . . . . . . . . . . . . . . . . . . . 36
1.2.1 Identifying characteristics . . . . . . . . . . . . . . . . . . . 4 4.1.7 Air suspension ECAS . . . . . . . . . . . . . . . . . . . . . 38
1.2.2 Vehicle identification number . . . . . . . . . . . . . . . . 5 4.1.8 Starting and switching off the engine . . . . . . . . . 39
1.2.3 Vehicle number . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.4 Wheel formulae . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.2 Quick reference guide for TGA . . . . . . . . . . . . 40
4.2.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . 9 4.2.2 Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3.1 Notes on dangers and risks . . . . . . . . . . . . . . . . . 9 4.2.3 Adjusting the seat, steering wheel and mirrors . . 44
1.3.2 Operational safety of the vehicle . . . . . . . . . . . . . . 9 4.2.4 Heating and ventilation . . . . . . . . . . . . . . . . . . . . 45
4.2.5 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2.6 Gearbox operation . . . . . . . . . . . . . . . . . . . . . . . 47
2 Quickly rectifying simple malfunctions . . 11 4.2.7 Air suspension ECAS . . . . . . . . . . . . . . . . . . . . . 49
4.2.8 Starting and stopping the engine . . . . . . . . . . . . 50
2.1 Fault messages on the instrument panel . . . . 11
2.1.1 Driver's display and check lamps . . . . . . . . . . . . 11 4.3 Breakdown assistance . . . . . . . . . . . . . . . . . . . 51
2.1.2 Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . 11 4.3.1 Tilting the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.3.2 Checking service products . . . . . . . . . . . . . . . . . 54
2.2 Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.3.3 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . 56
2.2.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4.3.4 Changing a wheel . . . . . . . . . . . . . . . . . . . . . . . . 56
2.2.2 Removing the cover from the battery box . . . . . . 23 4.3.5 Tow-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.2.3 Connecting terminals . . . . . . . . . . . . . . . . . . . . . 23
4.4 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.4.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.4.2 Releasing spring-loaded accumulators . . . . . . . . 62
3 Disconnecting the driveline . . . . . . . . . . . 25
4.4.3 Towing with a towing bar . . . . . . . . . . . . . . . . . . 66
3.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4.4.4 Towing with the front of the vehicle lifted . . . . . . . 70
4.4.5 Towing with the rear of the vehicle raised . . . . . . 79
3.2 Removing the propshaft . . . . . . . . . . . . . . . . . 26 4.4.6 Connecting pneumatic brake systems . . . . . . . . 85
3.2.1 Installation positions . . . . . . . . . . . . . . . . . . . . . . 26
3.2.2 Removing the propshaft . . . . . . . . . . . . . . . . . . . 26 4.5 Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.5.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.3 Removing axle shafts . . . . . . . . . . . . . . . . . . . . 27 4.5.2 Suitable force application points . . . . . . . . . . . . . 91
3.3.1 Installation positions . . . . . . . . . . . . . . . . . . . . . . 27 4.5.3 Pulling the vehicle forwards . . . . . . . . . . . . . . . 100
3.3.2 Special tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4.5.4 Pulling the vehicle backwards . . . . . . . . . . . . . . 101
3.3.3 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 4.5.5 Righting the vehicle . . . . . . . . . . . . . . . . . . . . . 101
3.3.4 Removing the hypoid axle shaft . . . . . . . . . . . . . 28 4.5.6 Lifting the vehicle . . . . . . . . . . . . . . . . . . . . . . . 102
3.3.5 Removing the planetary final drive shaft . . . . . . . 29 4.5.7 Lifting the vehicle high . . . . . . . . . . . . . . . . . . . 102
5 Series TGL and TGM . . . . . . . . . . . . . . . 103 6 Appendix . . . . . . . . . . . . . . . . . . . . . . . . 145
5.1 Quick reference guide . . . . . . . . . . . . . . . . . . 103 6.1 Tools and materials . . . . . . . . . . . . . . . . . . . . 145
5.1.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 6.1.1 Disconnecting the driveline . . . . . . . . . . . . . . . . 145
5.1.2 Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 6.1.2 Connecting brake compressed air systems . . . . 145
5.1.3 Adjusting the seat, steering wheel and mirrors . 105 6.1.3 TGX, TGS and TGA series . . . . . . . . . . . . . . . . . 146
5.1.4 Heating and ventilation . . . . . . . . . . . . . . . . . . . 106 6.1.4 Series TGL/TGM . . . . . . . . . . . . . . . . . . . . . . . 146
5.1.5 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 6.1.5 Reference addresses for other manufacturers . . 146
5.1.6 Gearbox operation . . . . . . . . . . . . . . . . . . . . . . 107
5.1.7 Air suspension ECAS . . . . . . . . . . . . . . . . . . . . 108 6.2 Safety components . . . . . . . . . . . . . . . . . . . . 147
5.1.8 Starting and switching off the engine . . . . . . . . 109 6.2.1 Operational safety of the vehicle . . . . . . . . . . . . 147
6.2.2 Safety components in the commercial vehicle . . 147
5.2 Breakdown assistance . . . . . . . . . . . . . . . . . . 110
5.2.1 Tilting the cab . . . . . . . . . . . . . . . . . . . . . . . . . . 110 6.3 Maximum permitted pulling force . . . . . . . . . 148
5.2.2 Checking service products . . . . . . . . . . . . . . . . 112 6.3.1 TGA series . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.2.3 Bleeding the fuel system . . . . . . . . . . . . . . . . . . 114 6.3.2 Series TGX, TGS . . . . . . . . . . . . . . . . . . . . . . . . 148
5.2.4 Changing a wheel . . . . . . . . . . . . . . . . . . . . . . . 115 6.3.3 Series TGL, TGM . . . . . . . . . . . . . . . . . . . . . . . 148
5.2.5 Tow-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.4 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.3 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.3.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.3.2 Releasing spring-loaded accumulators . . . . . . . 119
5.3.3 Towing with a towing bar . . . . . . . . . . . . . . . . . 123
5.3.4 Towing with the front of the vehicle lifted . . . . . . 125
5.3.5 Towing with the rear of the vehicle raised . . . . . 129
5.3.6 Connecting pneumatic brake systems . . . . . . . 133
5.4 Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

5.4.1 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.4.2 Suitable force application points . . . . . . . . . . . . 138
5.4.3 Removing the front bumper . . . . . . . . . . . . . . . 140
5.4.4 Pulling the vehicle forwards . . . . . . . . . . . . . . . 141
5.4.5 Pulling the vehicle backwards . . . . . . . . . . . . . . 141
5.4.6 Righting the vehicle . . . . . . . . . . . . . . . . . . . . . 142
5.4.7 Lifting the vehicle . . . . . . . . . . . . . . . . . . . . . . . 142
5.4.8 Lifting the vehicle high . . . . . . . . . . . . . . . . . . . 143
1
Notes
2
1 General information
1.1 About this handbook
1.1.1 Content 1.1.3 Technical status

This mobility handbook is intended to allow proficient and 09/2011 2nd edition Trucknology mobile
efficient undertaking of breakdown assistance, towing or Other MAN publications on this topic:
recovery measures on the MAN vehicle series TGX, TGS, Recommendations for towing and recovering MAN trucks
TGA, TGL and TGM. and buses, 1st edition 1996, 2nd edition 2002
Depending on the severity of the damage, these

instructions are intended to make it easy for the reader 1.1.4 Key to symbols
to rectify faults on the spot, tow or recover the vehicle. Different types of information are identified in order to
However, it is not possible to deal with all possible facilitate legibility and clarity.
problems. The actions to take on the spot, in particular
during recovery operations, are subject to the judgement of Sentences which start with a yellow block contain
the breakdown and towing personnel. procedural instructions.
When "towing" is referred to in this handbook, the technical Carry out procedural instructions in the sequence
recommendations given also apply to towing measures described.
undertaken for the purpose of vehicle delivery subject to
compliance with statutory regulations and approvals. The following information is preceded by a dash:
Lists
Descriptions of statuses
1.1.2 Liability Descriptions of previous work steps
This mobility manual is intended for qualified and Preconditions for actions described subsequently
experienced breakdown and towing personnel, motor
vehicle service companies and vehicle owners with an Registered trademarks
interest in the issue. It is assumed that knowledge of the The trademarks and logos below may be used in this
relevant regulations and guidelines is in place, and that manual. They are registered by MAN.
these regulations and guidelines will be followed.
Due to the wide variety of recovery measures, the person(s) MAN HydroDrive
undertaking the work is/are responsible for deciding on MAN TipMatic
what action to take on the spot. MAN cannot offer any MAN AdBlue
compensation for damage or warranty claims to cover
the consequences of incorrectly undertaken breakdown
assistance, towing or recovery measures.
3
1.2 Vehicle identification
1.2.1 Identifying characteristics

In order to be able to take appropriate measures at the
breakdown site, it is necessary for the breakdown or towing
personnel to take account of the most important equipment
and design features of the damaged vehicles, e.g.:
Axle constructions (e.g. rear trailing axle)
Wheel formula, i.e. number of existing, driven and
steered wheels (e.g. 4

x

2); possibly with MAN Hydro-
Drive front-axle drive in the TGX, TGS or TGA series
Suspension type, differentiated according to axles (e.g. TGX with plastic bumper (mostly on-road vehicles, TGS similar)
leaf suspension at front and air suspension at rear)
In TGX, TGS or TGA series: Plastic bumpers at front
(with the possibility of attaching towing eyes) or steel
bumpers (with towing jaw)
As a rule, the vehicle must be described exactly in case

of questions to MAN customer service. MAN customer
service is able to identify the damaged vehicle clearly
based on the vehicle identification number (chassis
number) or the vehicle number.The type designation on
the cab door is not sufficient to identify the vehicle.
TGS with steel bumpers (mostly construction site vehicles, TGX similar)
4
1.2.2 Vehicle identification number

The 17-digit vehicle identification number (abbreviated as
VIN or, in German, FIN) is frequently also referred to as the
chassis number.
It contains a 3-digit code from the 4th to 6th digits, which
is 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, it
starts with N.
For example:
WMA03SZZX7M490229 on a vehicle in the TGS series Vehicle identification number in the longitudinal member (example TGX)
WMAH05ZZZ9K000435 on a vehicle in the TGA series
WMAN12ZZ75Y150456 on a vehicle in the TGL series
Locations
Official vehicle documents
Front right longitudinal member, ahead of the front axle
Type plate (1) on the B-pillar (door frame), co-driver's 1
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
Type plate in the door frame (example TGS)
5
1.2.3 Vehicle number

The 7-digit vehicle number describes the technical equip-
ment 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 7-digit number on the longitudinal member (example TGA)
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
6
1.2.4 Wheel formulae

The wheel formula identifies the number of existing, driven
and steered wheels. Although the wheel formula is a
commonly used term, it is not standardised.
The number of steered wheels is only given in the wheel
formula if more than two axles are not driven. This means
there are leading or trailing axles fitted in addition to
steered front wheels. A leading axle is positioned ahead of
a driven rear axle unit, whereas a trailing axle is positioned
after the driven rear axle unit. A slash "/" stands for a
leading axle, a dash "-" stands for a trailing axle. If a chassis
has a leading and trailing axle, then the number of steered Example: Semitrailer tractor TGS, two of four wheels driven, two wheels
steered (wheel formula 4x2)
wheels is specified with a - .
In hydrostatic front axle drive (MAN HydroDrive), the wheel

formula is additionally specified with an H.
Example: 6x4H = one front axle with hydrostatic drive, two
rear axles, of which one is driven.
Vehicles with hydrostatic front axle drive can also be
identified by means of the special wheel hubs.
Vehicle with MAN HydroDrive: Front wheel hub with hydraulic wheel hub
motor
7
Vehicles offered by MAN
Wheel formula Explanation

4x2 Two-axle vehicle with one driven axle
4x4 Two-axle vehicle with two driven axles "all-wheel drive"
4x4H Two-axle vehicle with two driven axles, front axle with hydrostatic drive
6x2 /2 Three-axle vehicle with non-steered front axles "pusher"
6x2 /4 Three-axle vehicle with steered leading axle
6x2-2 Three-axle vehicle with non-steered trailing axle
6x2-4 Three-axle vehicle with steered trailing axle
6x4/4 Three-axle vehicle with drive to two axles, steered front axle
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 Three-axle vehicle with all-wheel drive
8x2-4 Four-axle vehicle, one driven axle, two steered front axles, non-steered trailing axle
Four-axle vehicle, one driven axle, two steered front axles, steered trailing axle
8x2-6
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
8
1.3 Safety instructions
1.3.1 Notes on dangers and risks 1.3.2 Operational safety of the vehicle
Important information that you must comply with is
specially marked: Warning!
Damage to safety components can lead to traffic
accidents with serious consequences!
Danger! When recovering and towing, always avoid
A danger note warns against immediate dangers applying force to safety components.
that can result in serious or fatal injuries! If this is not possible:
The instructions for preventing or avoiding the Have the affected safety components checked
dangers must be followed. by an authorised MAN Service workshop.
List of safety components see appendix 6.2
Warning! Vehicles that have been recovered or towed
A warning note indicates risks that can lead to must always be checked by an authorised
serious or fatal injuries! MAN Service workshop to make sure they are
The instructions for protecting the people in correct technical condition and have not
affected must be followed. been damaged.
Caution! Warning!
A caution note indicates risks that can lead to Incorrect interventions into the vehicle technology
damage to property or slight injuries to personnel! can threaten the operational safety of the vehicle
It is essential to follow the instructions for and lead to traffic accidents! Interventions in
prevention of damage. electric and electronic components as well as
their software can also impair indirectly affected
systems.
Do not attempt any repairs if the procedure is
unclear.
Comply with the relevant accident prevention
regulations, e.g. BGV D 8 "Winches, lifting and
towing equipment"
Have the vehicle checked at a MAN Service
workshop Important points to check:
Safety components
Cardan shafts which were removed
9
Notes
10
2 Quickly rectifying simple malfunctions
2.1 Fault messages on the instrument panel
1 2
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,
TGS, TGA) and 5.2 (TGL, TGM)
2.1.1 Driver's display and check lamps

The indications on the driver's display (1) and in the panel
of check lamps (2) tells the driver about the status of the Driver's display and panel of check lamps (remark on the display:
Graphic shows the instrument for TGL and TGM. The information applies
vehicle. The information can be displayed as texts and/or
accordingly to the heavy range).
symbols.
The driver's display is divided up into rows and display
areas:
It shows symbols and plain text instructions about safety,
current functions (e.g. radio), workshop displays and
operating information (e.g. gear display).
The panel of check lamps contains check lamps and
warning lights. These are red, yellow, blue or green and
can show a steady light or flash.
The number of lamps may differ, depending on the vehicle

equipment.
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.
Indications on the driver's display and panel of check lamps,

see tables. Note: Pay attention to the display versions!
11
Indications on the driver's display and panel of check lamps

in TGX and TGS as well as TGL and TGM from year of manufacture 2009
Driver's display Check lamps Meaning Procedure

Symbol Text message
Run engine at increased revs
Circ. 1, 2, 3, 4
Air pressure too low in a brake until shut-off pressure is reached
pressure Flashes
Red circuit (message goes out).
too low red
Obtain workshop assistance.
Run engine at increased revs
Unexpected behaviour of air until shut-off pressure is reached
Reservoir pressureK3 Flashes
Red pressure in brake circuit 3 (message goes out).
red
Obtain workshop assistance.
Connection between instrument Check fuse.

Malfunction Red
Flashes panel and central electrical Obtain workshop assistance
electrical system Yellow
red system has failed. immediately.
Check fuse.
On-board computer Central on-board computer has
Flashes red
Obtain workshop assistance
malfunction failed.
immediately.
Check fuse.
Malfunction Vehicle management computer
veh. man. computer Flashes red has failed.
immediately.
Check fuse.
Malfunction
Engine control unit has failed. Obtain workshop assistance
engine ctrl. unit Flashes red
immediately.
Check fuse.
Malfunction
Gearbox ECU has failed. Obtain workshop assistance
gearbox ECU Flashes red
immediately.
Vehicle cannot be driven!
Stop immediately, taking into
account situation on road.

Malfunction Hydraulic steering assistance has Only drive forwards.
rear axle steering Flashes red failed. Continued driving, even with steered
rear axle lifted, is not permitted!
immediately.
Defective switch Electrical connection to hazard Obtain workshop assistance
haz.warn. lights Flashes red warning light switch is defective. immediately.
Electrical connection to hazard
Defective switch Obtain workshop assistance
headlight low beam switch is
low beam Flashes red immediately.
defective.
Check fuse.
Headlight low beam Left-hand/right-hand low beam or Change bulb immediately.
left/right Flashes red winter service lamp has failed. Obtain workshop assistance if
necessary.
12
Indications on driver's display and panel of check lamps


Symbol Text message
Check fuse.
Malfunction Torque converter and clutch
gearbox ECU Red Yellow system (WSK) has failed.
immediately.
Drive slowly and carefully.
Note different braking
Electronic brake system characteristics.
Limp-home brake
incl.ABS, ASR and ESP on Greater tendency for wheels to
control unit Red Red
tractor has failed. lock.
immediately.
Trailer brake Trailer braking system has failed. Drive slowly and carefully.
Red Red
Restricted tractor ABS
Tractor ABS Drive slowly and carefully.
Yellow Yellow functioning.
Trailer ABS Trailer ABS function has failed. Drive slowly and carefully.
Yellow Yellow
Switch off Intarder/retarder and
deactivateMAN BrakeMatic.
Run engine at increased revs to
Retarder temperature Oil temperature in Intarder/
improve cooling.
too high Flashes red retarder is much too high.
After cooling down:
Check oil level in gearbox, top up
oil if necessary.
deactivateMAN BrakeMatic.
Retarder temperature Oil temperature in Intarder/ Increase engine speed to improve

too high retarder is too high. cooling.
Check oil level in gearbox, top up
oil if necessary.
Check fuses.
Malfunction Primary retarder:
sust.-action brake Red Retarder has failed.
immediately if necessary.
Retarder power Shift to a lower gear (increase
Retarder torque is reduced.
reduced engine revs) to improve cooling.
Start off and drive carefully!
Malfunction Tractor ESP or ASR function has Check fuse.
ESP Red Yellow failed. Obtain workshop assistance
immediately.
13

Driver's display Checklamps Meaning Procedure

Symbol Text message
Only drive vehicle at walking pace
Malfunction Electronically controlled air and only for short distances
air suspension Red Red suspension has failed. Obtain workshop assistance
immediately.
Switch off unrequired loads.
Charge voltage Charge voltage is too low when
Obtain workshop assistance if
too low Yellow engine is running.
necessary.
Check engine oil level and top up
Oil pressure oil if necessary.
Flashes Engine oil pressure is too low.
too low Red Obtain workshop assistance if
red
necessary.
Shift to a lower gear to improve
cooling.
Engine oil temperature
Engine oil temperature is too high. Run engine at increased speed.
too high Red Red
Check engine oil and coolant
levels.
Oil level too low or has
Check engine
significantly deviated from Check engine oil level.
oil level Yellow
permitted minimum value.
cooling.
Coolant temperature
Coolant temperature is too high. Switch off engine and let it cool
too high Red Red
down.
Check coolant level.
Coolant level There is not enough fluid in
Top up coolant.
too low Yellow cooling system.
Change
Air filter is clogged. Change air filter.
air filter Yellow Yellow
Clutch oil level
Reservoir level is too low. Top up oil.
too low Red
14


Symbol Text message
deactivate MAN BrakeMatic.
cooling.
Gearbox temperature Gear oil temperature is much too
too high Flashes red high.
account situation on road.
Run engine at increased speed
Check oil level and top up oil if
necessary.
Insufficient air pressure at
Air pressure Do not set vehicle in motion.
automated gearbox (circuit 4).
DO NOT SHIFT Red Red Obtain workshop assistance.
Gear changes not possible.
Gearbox temperature deactivate MAN BrakeMatic.
Gear oil temperature is too high.
too high Yellow Check gearbox oil level, top up
oil.
Steer oil press.
Not enough oil in power steering. Obtain workshop assistance
too low Red
immediately.
Steer oil press. Check oil level, top up if
Not enough oil in power steering.
too low Yellow necessary.
Steering oil level
Not enough oil in power steering. Obtain workshop assistance.
fault Yellow
Tipper operation Flashes Tipper body is operating. Lower tipper body completely.
Red
red
Liftgate is open or not fully

Lock liftgate Flashes Lock liftgate correctly.
Red locked.
red
Check fuse.
Turn indicator tractor Failure of a left-hand/right-hand
Change bulb immediately.
left/right failure Yellow tractor indicator.
Perform a light test.
Check fuse.
Turn indicator, trailer Failure of a left/right turn trailer
Change bulb immediately.
left/right failure Yellow indicator.
Perform a light test.
Side marking Failure of at least one of left/right- Check fuse.

fault Yellow hand side marker lights on tractor. Change LED block immediately.
15


Symbol Text message
Track/trailer brake Tractor/trailer brake lamp has Check fuse.
lamp failure Red failed. Change bulb immediately.
Check fuse.
Tachograph EU monitoring device
malfunction Red (tachograph) has failed.
immediately.
EU monitoring device Obtain workshop assistance
Check tachograph
Red (tachograph) is not OK. immediately.
Check tyre inflation pressure.
Malfunction Tyre pressure monitoring system If necessary, correct inflation
tyre pressure mon. Yellow Yellow has failed. pressure.
Check fuse.
Rapid pressure loss from at least account situation on road.
Tyre defective
Yellow Yellow one tyre. Check tyre inflation pressure.
Change wheel if necessary.
Stop at a suitable location.
Pressure loss from at least one
Tyres Check tyre inflation pressure.
Yellow Yellow tyre.
Check
Check tyre pressure. If necessary, correct inflation
tyre pressure Yellow
pressure.
Stop vehicle, taking into account
Tyre pressure Tyre pressure is too low or too situation on road.
too low/high Yellow Yellow high. Correct tyre inflation pressure.
Tyre pressure is too low or too
Trailer tyres If necessary, correct inflation
Yellow high.
pressure.
16

in TGA as well as TGL and TGM before year of manufacture 2009

Symbol Text message
Run engine at increased idling speed
Circ. 1, 2, 3, 4
Insufficient air pressure in one until reaching nominal pressure.
pressure Flashes
Red of brake circuits If this is not reached, drive to a MAN
too low red
Service workshop or tow if necessary.
If pressure drops below 6 bar:
Run engine at increased idling speed
Circ. 1, 2, 3, 4 Unexpected behaviour of air
Flashes until reaching nominal pressure.
pressure Red pressure in a brake circuit
red If this is not reached, drive to a MAN
Service workshop or tow if necessary.
Check fuses and renew if necessary.
Otherwise, drive to a MAN Service
Air preparation failed, brake
PSC failure Flashes workshop or tow if necessary, and
Red circuits without air pressure
red pressurise with air from an external
source.
Red Connection between Check fuses and renew if necessary.

CAN interconnect
Flashes Yellow instrument panel and central Otherwise drive to a MAN Service
failure
red electrical system has failed workshop or tow if necessary.
Yellow
Central on-board computer
ZBR failure Otherwise drive to a MAN Service
Flashes red has failed
workshop or tow if necessary.
Vehicle management compu-
FFR failure Otherwise drive to a MAN Service
Flashes red ter failure
EDC failure EDC has failed Otherwise drive to a MAN Service
Flashes red
EDC S failure EDC S failed Otherwise drive to a MAN Service
Flashes red
Cooling system Check cooling water system.

Engine cooling has failed
Stop engine Flashes red Tow if necessary, with front lifted.
Control unit for gearbox has
TCU failure Otherwise drive to a MAN Service
Flashes red failed
17


Symbol Text message
Trailing/leading axle Steered leading/trailing axle no Drive to a MAN Service
failure Flashes red longer steers. workshop.
Defective switch Electrical connection to hazard Drive to a MAN Service
haz.warn. lights Flashes red warning light switch defective workshop.
Tow if lighting is required.
Defective switch Electrical connection to low beam
Otherwise drive to a MAN Service
low beam Red switch defective
Change bulb.
Check fuses and renew if
Low beam (left, right) Left-hand/right-hand low beam
necessary.
failure Yellow headlight has failed
Otherwise drive to a MAN Service
WSK
Converter lock-up clutch failed necessary.
failure Red Yellow
Otherwise tow.
EBS
Electronic brake system failed Drive slowly and carefully.
emergency prog. Red Red
Trailer brake Trailer brake system has failed Drive slowly and carefully.
Red Red
Trailer brake
Trailer brake temperature too high Drive slowly and carefully.
temperature Yellow
Tractor ABS Restricted tractor ABS
failure Yellow Yellow functioning.
1 Trailer ABS Trailer ABS function has failed. Drive slowly and carefully.
Yellow Yellow
Deactivate retarder.
Retarder temperature Oil temperature in retarder much improve cooling.
too high Flashes red too high In vehicles with Intarder:
Check oil level in gearbox and top
up oil if necessary.
Deactivate retarder.
Retarder temperature Oil temperature in retarder too improve cooling.

too high high In vehicles with Intarder:
Check oil level in gearbox and top
up oil if necessary.
18


Symbol Text message
RET P necessary.
Primary retarder has failed
failure Red Otherwise drive to a MAN Service
workshop.
RET S necessary.
Secondary retarder has failed
failure Red Otherwise drive to a MAN Service
workshop.
Retarder power Shift to a lower gear to cool
Retarder torque limitation
reduced down.
necessary.
Otherwise drive carefully.
ESP Vehicles with super-wide tyres
Red/ ESP failed
failure Yellow (single tyres) on rear axle: Only
yellow
continue driving at max. 60k m/h.
Drive to a MAN Service
workshop.
ECAS Electronically controlled air
Drive to a MAN Service
failure Red Red suspension has failed
workshop.
Increase engine speed until mes-
Battery
Battery undervoltage sage disappears.
undervoltage Yellow
Check battery electrolyte level.
Check engine oil level, top up if
necessary.
Oil pressure
Flashes Engine oil pressure too low If message does not go out: drive
too low Red
red to a MAN Service workshop, tow
if necessary.
Oil pressure Check engine oil level, drain if

Flashes Engine oil pressure too high
too high Red necessary.
red
Increase engine speed to improve
Engine oil temperature cooling.
Engine oil temperature too high
too high Red Check engine oil and coolant
levels.
Check
Engine oil level too high/too low Check engine oil level.
engine oil level Yellow
Cooling system Coolant temperature too high cooling.
Flashes red
19


Symbol Text message
Coolant temperature
Coolant temperature too high cooling.
too high Red
Cooling water level Not enough coolant in cooling
Top up coolant.
too low Yellow system
Change
Air filter blocked Change or clean air filter.
air filter Yellow Yellow
Clutch oil level Fill level in clutch oil reservoir too Check oil level, top up if
too low Red low necessary.
Stop.
Gearbox temperature Gearbox oil temperature much
Check oil level, top up if
too high Flashes red too high
necessary.
Air pressure No air pressure at automatic
Tow.
DO NOT SHIFT Red gearbox, gearshift not possible
Switch off Intarder/retarder/
Gearbox temperature Oil temperature in gearbox too MANBrakeMatic.
too high Yellow high Check oil level, top up if
necessary.
Steer oil press. Check oil level, top up if
Not enough oil in power steering
too low Red necessary.
Steering oil Check oil level, top up if
Not enough oil in power steering
level fault Yellow necessary.
Tipper operation Flashes Tipper body operating Lower tipper body.

Red
red
Lock liftgate Flashes Liftgate not locked Lock liftgate.

Red
red
Tractor turn indicator Failure of a right or left turn Change bulb.

right/left failure Yellow indicator bulb in tractor Check fuse.
Trailer turn indicator Failure of a right or left turn Change bulb.

right/left failure Yellow indicator bulb in trailer Check fuse.
Fault side marker Failure of at least one side marker Change LED block
right/left Yellow light Check fuse.
Brake lampdoes Change bulb.

Brake lamp has failed
not function Red Check fuse.
Tractor brake Change bulb.

Tractor/trailer brake lamp failed
lampfailure Red Check fuse.
Check TCO EC monitoring device failed Check fuse.

Red
20
2.2 Jump starting


Symbol Text message
TPM Tyre pressure monitoring system
Check fuse.
failure Red failed
Tyre Rapid pressure loss from at least Stop.

defective Yellow one tyre Check tyres, repair or change.
Check Pressure loss from at least one Stop.

tyres Yellow tyre Check tyres, repair or change.
Check Check tyre pressure, correct if
Check tyre pressure.
tyre pressure Yellow necessary.
Tyre pressure Check tyre pressure, correct if
Tyre pressure too low
too low Yellow necessary.
Tyre pressure Check tyre pressure, correct if
Tyre pressure too high
too high Yellow necessary.
Check Check tyre pressure, correct if
Check tyre pressure.
trailer tyres Yellow necessary.
21
2.2 Jump starting
2.2.1 Notes
Danger! Warning!
Danger of acid burns! Batteries contain corrosive Risk of explosion due to oxyhydrogen gas! A
acid! highly-explosive oxyhydrogen gas mixture can be
Wear suitable protective clothing as well formed when jump starting. Keep away sources of
as acid-resistant protective gloves and eye fire, sparks and naked flames! Do not smoke!
protection. Take care not to generate any sparks when
Do not tip batteries; acid may emerge from the connecting and disconnecting electrical
vent holes. consumers or measuring devices directly on
Follow the instructions in the Operators the battery terminals.
Manual and documentation provided by the Before connecting or disconnecting the
battery manufacturer. batteries, switch off any consumers which are
directly connected to the batteries (terminal
30). Such consumers include the tachograph,
interior lighting, etc. Switch them off by
removing the corresponding fuse from the
central electrical system.
Remove the earth connection first.
Take care to avoid short-circuits due to
incorrect polarity and working with open-end
spanners. Do not remove terminal covers
unless really necessary.
Fit the earth strap last when reconnecting.
Wear eye or face protection
Keep children away from acid and batteries
Ensure adequate ventilation
Only use standardised jump leads (e.g. DIN
72553).
Use the instructions for use of the jump leads.
Only use batteries with the same nominal

voltage (24V).
Never use a boost-charger or jump-starting

unit.
22
2.2 Jump starting
2.2.2 Removing the cover from the battery box

Open the bayonet locks of the battery box cover (1).
Remove the cover.
1 1
2.2.3 Connecting terminals
(a) Batteries in the vehicle providing the jump start
(b) Batteries of the vehicle receiving the jump start
Precondition:
Both engines are switched off
Battery box
Connect the positive terminals (2) and (3).
Connect the negative terminal of the charged battery
(4) to a bare metal point on the engine block or gearbox a
(earth connection on the starter or clutch bell housing).
2
Do not connect the earth cable to the frame.
If jump leads are used in vehicles with a battery master

4
switch then the cable can also be connected to the
battery negative terminal (5) of the vehicle receiving the
jump start, providing the battery master switch is turned
off. Only then operate the battery master switch. 3
Start the engine of the vehicle providing the jump start. 5

Attempt to start the engine of the vehicle receiving the
b
jump start for max. 15 seconds.
Connecting terminals
23
Notes
24
3 Disconnecting the driveline
3.1 Notes
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.
Secure the vehicle to prevent it from rolling
away before disconnecting the driveline.
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
Always disconnect the driveline before towing.
If this is not possible at the location in question:

Engage the high range if possible.
Tow the vehicle at a maximum speed of
10km/h for maximum 1km (no towing is
possible in vehicles with automatic gearshift
control).
25
3.2 Removing the propshaft
3.2.1 Installation positions

Between the gearbox and rear axle(1).
1
If two rear axles are driven:

Between the gearbox and forward rear axle(2).
In addition in vehicles with all-wheel drive:

Between the transfer case and the front axle(3).
3 2
If two front axles are driven:

Between the transfer case and rearward front axle
Vehicles with MAN HydroDrive

Cardan shaftbetween the gearbox and rear axle(4). Flange connections of thecardan shafts (illustration shows the TGX)
The hydraulic front axle drive(5)is not disconnected.
3.2.2 Removing the propshaft

Mark the installation position of the cardan shaft on the
flanges(6). 4
If the cardan shaft has an intermediate bearing:
Disconnect the intermediate bearing from the frame and 5
leave it on the cardan shaft. Do not split the bearing.
Support the cardan shaftor tie it up in order to prevent
it from dropping down when the flange connections are TGS semitrailer tractor with MAN HydroDrive
disconnected.
Remove clamping bolts(7)from the flange connections.
Remove the cardan shaftand store it safely.
6
After towing
Have the cardan shaftreinstalled in the marked
orientation at a MAN Service workshop
Note
If the driveline cannot be disconnected in this way,
e.g. because there is no possible access to the
flange connection:
Remove the axle shafts,see chapter 3.3.
7
Flange connection on thecardan shaft
26
3.3 Removing axle shafts
3.3.1 Installation positions

Left and right on all driven axles; up to eight axle shafts
must be removed from four-axle vehicles.
3.3.2 Special tool

Octagonal socket(1)for the switch of thetransverse
differential lock(parts no.80.99603.0261)
Pressure spindle(4) M 18x1.5 for blocking
1 2 3
thedifferential box(parts no.80.99613.0027);
onepressure spindleis required for each affected axle.
Remove the pressure switch
(illustration shows thedifferential boxof aplanetary final drive axle; the
In addition for removal of planetary final drive shafts:
described procedure is identical in hypoid andplanetary final drive axles)
Oil filler tank (parts no.80.99613.0027)
Internal retaining ring pliers(parts no.08.04046.9000)
Support handleandstud boltfor pulling out the axle
shafts (parts nos.80.99617.0005, 06.06138.0712);
alternatively: bolt M8x120 and nut M8
In addition for removal of hypoid axle shafts:

Dummy covers for sealing the wheel hub opening. The
dummy covers are DIY parts. Two dummy covers are
required for each affected axle.
3.3.3 Preparations
The corresponding differential box must be blocked in 4 5
order to allow the axle shafts to be re-installed after towing.
Blocking the differential box
On thedifferential box,remove pressure switch(2)with
octagonal socket (1), remove seal(3).
Screw pressure spindle(4)into theselector cylinder
cover(5)until the sliding sleeveengages.
Thedifferential boxis now blocked.
27
3.3.4 Removing the hypoid axle shaft

Hypoid axles have a single axle ratio; they are used above
all in on-road vehicles. 2
1
Current series (with grease lubrication of the axles):
Remove the mounting bolts.
Remove the axle shaft.
Seal the wheel hub opening in order to prevent dirt
getting into the wheel bearing.
Use dummy covers for this.
Remove the hypoid axle shaft (example shows the older series with oil
Older series (with oil lubrication of the axles,cast lubrication)
projection(2)on the rim):
Keep a suitable, clean collecting tank (approx. 3l) for
the oil which drains out.
Turn the wheel so theoil drain hole(1)is not at the
bottom. A residual amount of oil must always remain
in the wheel bearing. Theoil drain holeis identified by
acast projection(2).
Remove the mounting bolts.
Collect all of the oil which drains out.
Remove the axle shaft.
Seal the oil drain holewith one of themounting bolts.
Seal the wheel hub opening in order to prevent dirt
getting into the wheel bearing. Use dummy covers to do
this.
The oil which drained out must be refilled after

installation of the axle, or disposed of in an
environmentally friendly manner.
28
3.3.5 Removing the planetary final drive shaft

Planetary final drive axles are axles with double ratios; they
are used in construction vehicles, for example.
Keep a suitable, clean collecting tank (approx. 3l) for

the oil which drains out.
Turn the wheel so theoil drain hole(5)is at the bottom.
Drain all the oil.
Unscrew end cover(1)and remove with sealing ring(2).
Screw the support handlewithstud boltinto the axle
shaft
or Removing the planetary final drive shaft
Screw bolt M8x120 (8)withlocknutinto the axle shaft,
tighten thelocknut.
Remove retaining ring(3). Useinternal retaining ring 3
4 4
pliersfor this purpose.
Remove shims andthrust washers(4), the number and
designs may be different from the illustration.
Document the arrangement and give the records to the
workshop for the purpose of assembly.
Pull out axle shaft(6) together withsun gear(7)of
theplanetary gearbox and axial bearings.
Clean the inside of theend cover.
Reinstall the end covertogether with the sealing ring in
order to prevent dirt getting into the wheel bearing. 5
Remove the oil filler plugfrom theend cover. 1 2
Refill the oil which drained out. Use an oil filler tank for
this purpose. Removing the end cover from the wheel hub
Screw the oil filler plugback into theend cover.
Note
Thesun gearand axial bearings are underspring
preload. If thesupport handle(or the bolt M8x120)
is removed, the springs can jump out and the
washers and the axial bearing can drop out.
Do not unscrew the support handle(or bolt)
until after the axle shaft has been installed in
the workshop.
6
8
7
Removing the axle shaft withsun gear
29
Notes
30
4 TGX, TGS and TGA series
4.1 Quick reference guide for TGX, TGS
1 2 3 4 5 6 7 8
4.1.1 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
Therefore, also read and comply with
theoperator's manual. 16 15 14 13 12 11 10
The same thing applies to the instructions
supplied by manufacturers of bodies and other Instrument panel in TGX and TGS (with AdBlue)
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
Using the menu

e.g. language changeover
Give key (1) a long press until the menu selection
appears.
Press key (1) briefly several times until "Language" is
selected.
Press key (2) briefly to confirm the selection.
Press key (1) to select the required language (short
press) and press key (2) to confirm.
The display at the bottom right shows the current key
assignment indicated by symbols.
Display
For information about the most important messages on
1 2
the display see chapter 2.1
Vehicles with multifunction steering wheel menu

operation
e.g. language changeover: Function keys on the instrument panel with Vehicle menu
Press key(4).
Press key (1 or 2) several times until "Language" is
selected.
Press key (3) to confirm the selection.
Press key (1 or 2) to select the required language and
press key (3) to confirm.
Function keys on the multifunction steering wheel with Vehicle menu
32
4.1.3 Adjusting the seat, steering wheel and

mirrors
1
Adjusting the seat

Comfort seats, Grammer
1 Adjust seat base angle 8 2
2 Adjust armrests
3 Adjust backrest angle
3
4 Adjust height of seat base 7
5 Adjust vertical damper (soft/hard)
6 Entry and exit aid (quick-lowering facility)
7 Adjust reclined position
6 5 4
8 Adjust front/back position
Controls for the Grammer seat with maximum equipment level
Comfort and luxury seats, Isringhausen
9 Adjust seat base angle
10 Adjust depth of the seat cushion
11 Adjust horizontal cushioning
12 Adjust armrests
9 10
13 Adjust angle of the top part of the backrest
15 Adjust lumbar support and lateral support
16 Adjust seat surface height
13
18 Entry and exit aid (quick-lowering facility) 14
11 12
19 Adjust reclined position 15
20 Adjust front/back position
20 15
Adjusting the steering wheel
19
There must be sufficient reservoir pressure in the
compressed air system in order to adjust the steering
18 17 16 15
wheel.
First set the drivers seat, then adapt the steering wheel Controls for the Isri seat with maximum equipment level
to the modified seat position.
Press the top of rocker button (21)
Adjust the height and reach of the steering wheel.
Release rocker button (21).
The steering wheel is locked again after about 21
5seconds.
Press the bottom of rocker button (21).
The steering wheel is locked more quickly.
Rocker button for locking and Steering wheel adjustment devices
unlocking
33
Adjusting the mirrors

1 Select mirror (left/right side) 2
2 Adjust mirror
3 Select mirror:
Kerb mirror/main mirror/wide-angle mirror
4 Switch mirror heating on/off 1
The check lamp in the switch lights up when the mirror 4
heating is turned on.
5 3
5 Mirror heating check lamp
6 Briefly moving the main mirror on the co-driver's side 6
The mirror swivels back to its starting position
automatically after about 30seconds or if you press the
key(1) again.
Door module
4.1.4 Heating, ventilation and air conditioning
Functions on the control panel 8 9 10 11 12 13 14

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 16 15
Independent Air Conditioning System

10 Set the temperature Controls for heating, ventilation and air conditioning
15 Refrigerant reservoir
19 Cool when engine is switched off
Auxiliary air heater (independent heater)

10 Set temperature, set values
17 Input mode (program)
18 Heat
34
1 2
4.1.5 Braking
Applying the parking brake

Push the lever (1) backwards until it engages.
The check lamp comes on.
Releasing the parking brake

Pull the lever catch (2). Applying the parking brake in the Releasing the parking brake
gearshift console
The lever automatically moves forwards into the
released position.
The check lamp goes out
Activating the engine brake

Press key (4 or 6).
Switching off the engine brake

Press key (4 or 6) again.
Retarder/Intarder
Increasing braking power gradually: Parking brake "check lamp" on the instrument panel
Press steering column switch (3 or 5) down.
Reducing braking power gradually: 3

5
Press steering column switch (3 or 5) up.

The "retarder operation" (7) symbol appears on the
display with the corresponding level.
4 6
Switching to full power:
Press key (4 or 6).
Sustained-action brake lever Sustained-action brake lever in
vehicles with multifunction steering
Switching off:
wheel
Hold steering column switch (3 or 5) upwards or press
key (4 or 6) again.
Retarder/Intarder level indication on the display
35
MAN BrakeMatic
BrakeMatic is switched on automatically after the ignition is 1
switched on. No check lamp in rocker button (1) comes on.
2
Switching off BrakeMatic
Press rocker button (1). Rocker button in a vehicle with Display showing BrakeMatic and
Intarder cruise control switched on
The check lamp in the rocker button lights up and
symbol (2) on the display goes out.
Switching on BrakeMatic
Press rocker button (1) again.
The check lamp in the rocker button goes out and -
#
symbol (2) appears on the display. #,
1
1,
4.1.6 Gearbox operation
MAN TipMatic DNR switch:

Drive, forwards: D
Manoeuvre, forwards: DM
Neutral: N MAN TipMatic drive/neutral/reverse switch
Drive, reverse: R
Manoeuvre, reverse: RM
4 5 6
Note %%
7.
,
Drive the vehicle in automatic mode if possible.

, -
43.
, -
.%% 43.
.%%
,$, , 7
Switching between automatic and manual mode: 2$3
Press key(4).
In vehicles with multifunction steering wheel: Press
3
handle (6).
Upshift: Steering column switch in vehicles Steering column switch in vehicles
without multifunctional steering with multifunctional steering wheel
One gear: Briefly pull steering column switch (3 or 5)
wheel
towards the steering wheel.
Several gears: Pull and hold the steering column switch.
Downshift:
One gear: Briefly press steering column switch (3 or 5)
away from the steering wheel.
Several gears: Push and hold the steering column
switch.
Display: "Automatic", in "neutral" Display: "Manual", 10th gear,

shift position maximum number of gears which
can be engaged (2 up and down)
36

Gearbox
1 Toggle switch (range-change group)
down: Gears 1 4 and reverse
-
up: Gears 5 8 3
2
2 Rocker switch (splitter group)
Front: splitter group high 1 1
Rear: splitter group low
3 ComfortShift key (only with MAN ComfortShift gearbox)
The shift pattern indicates the position of the shift lever in Shift lever
the individual gears.
Gear display:
5 6 7
4 Low range
5 High range
6 Engaged gear
"N": Neutral
"R": Reverse
"": No gear engaged)
7 Splitter group high
4 8
8 Splitter group low
MAN ServoShift manual gearbox:

Depress the clutch fully for moving off and changing
gear.
Symbols on the display
MAN ComfortShift manual gearbox:

gear at speeds less than 5km/h!
Depress the clutch fully for changing gear at speeds
greater than 5km/h or
Press ComfortShift key (3) until the gearshift has been
completed.
37
6 8
4.1.7 Air suspension ECAS
Danger of accidents!
The braking response is different when the vehicle 5 7
frame is lowered! 4
If the vehicle has a lowered frame, it must only
3 9
be moved slowly and carefully.
Return the frame to the ride height before driving. 2
10
1
If the frame is fully raised, this shifts the centre of
gravity and leads to uncontrollable changes in the
driving behaviour! ECAS remote control
Do not move the vehicle when its frame is
raised above the ride height.
Return the frame to the ride height before driving.
Incorrect or inadvertent actuation of the air

suspension can result in serious accidents!
Before starting to drive, securely press the
remote control into the holder on the console of
the driver's seat.
ECAS remote control

1 Manual lifting
2 Manual lowering
3 Memory key 1
4 Memory key 2
5 Raise/lower the vehicle at front (only with full air
suspension)
6 Associated check lamp
7 Raise/lower vehicle at rear
9 Ride height
10 Stop key
Setting the ride height

Press key (7) and, if fitted, key (5).
The associated check lamps (8), (6) light up.
Press key (9).
The frame is moved to the ride height.
Press keys (7) and (5) again to switch off ECAS remote
control.
The associated check lamps (8), (6) go out.
38
2
4.1.8 Starting and switching off the engine
3
Ignition lock
1
Ignition key positions:
1 Zero position, inserting or removing the ignition key 4
2 Steering wheel unlocked
3 Driving position, ignition switched on
4 Start position
Starting the engine

Switch on the mechanical battery master switch if
necessary. Ignition key positions
Switch on the electrical battery isolator switch if
necessary.
Unlock the steering wheel.
Apply the parking brake.
Shift the gearbox to neutral "N".
Turn the ignition key to driving position (3).
Only in vehicles with a flame start system:
If the engine is cold, wait until
the heating-up procedure has started,
an audible signal sounds and
the "flame start" check lamp (5) goes out.
Turn the ignition key to start position (4), start the
engine and release the ignition key. 5
Stopping the engine

If the engine has been running under considerable load, Only in vehicles with a flame start system: "flame start" check lamp
on the display
do not stop it immediately but let it idle briefly first.
Stop the vehicle.
Turn the ignition key to zero position (1)
This stops the engine.
Locking the steering
If the vehicle is fitted with special equipment according to

GGVSE (European agreement for cross-border transport of
dangerous goods by road/rail):
In an emergency, the engine can be stopped using the
emergency off switch at the driver's station or at the
wing extension
39
4.2 Quick reference guide for TGA
3 4 5 6 7
4.2.1 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 2 8
notes contained therein. 1 9
Therefore, also read and comply with
theoperator's manual. 15 14 13 12 11 10
supplied by manufacturers of bodies and other Instrument panel (Highline version; Baseline with small display area (5) and
additional panel of check lamps)
equipment.
lamps.
16
4.2.2 Instrument panel
Instrument panel
1 Hazard warning light
2 Fog lights and rear fog light 17
3 Headlight beam regulator
4 Display of time, outdoor temperature or charge pressure
5 Display
6 Milometer, trip counter, speed in mph
7 Light test
8 BrakeMatic Highline display menu operating unit
9 Cruise control and road speed limiter
10 Baseline: Operate the Vehicle menu,
confirm yellow messages on the display,
km/h or mph display
11 Baseline: Calling up and using the Vehicle menu
12 Pressure indicator in brake circuit II
13 Pressure indicator in brake circuit I
14 Instrument lighting
15 Time and outside temperature
16 Highline: Calling up the Vehicle menu
17 Highline: Rotary/pushbutton switch for menu operation
40
Using the menu

Baseline:
appears.
Press key (11) briefly several times until "Vehicle
configuration" is selected.
Press key (11) to select the "Language" menu item.
Press key (10) to confirm. 11 10
press) and press key (10) to confirm. Instrument panel (Highline version; Baseline with small display area (5) and
additional panel of check lamps)
Highline:
Press key (16)
The menu selection appears.
Turn rotary/pushbutton switch (17) until "Vehicle
configuration" is selected.
16
Press rotary/pushbutton switch (17) briefly to confirm
the selection.
Press rotary/pushbutton switch (17) to select the
"Language" menu item.
Press to confirm 17
Use rotary/pushbutton switch (17) to select the required
language and confirm by pressing.
Display
For information about the most important messages on Highline display menu operating unit
41
3 4 5 6 7 8
"Stoneridge" instrument panel

Baseline:
2
1 Hazard warning light 9
2 Fog lights and rear fog light

3 Rev counter
4 Display of time/outside temperature
5 Display
6 Check lamps 1 10
7 Speedometer
18 17 16 15 14 13 12 11
8 Milometer, trip counter, speed in mph
9 Light test
10 Headlight beam regulator Baseline instrument panel
11 Pressure indicator in brake circuit II
13 Calling up and using the Vehicle menu
14 Pressure indicator in brake circuit I
16 Instrument lighting
17 Time, outside temperature changeover switch
18 Check the fuel
42
Using the menu

e.g. language changeover:
appears.
selected.
13 12
"Stoneridge" Baseline instrument panel
Display

operation
e.g. language changeover:
Press key(17).
selected.
Press key (14 or 15) to select the required language and
press key (16) to confirm.
Multifunction steering wheel
14
15
16
17
Function keys on the multifunction steering wheel
43
4.2.3 Adjusting the seat, steering wheel and

1
mirrors 2
Adjusting the seat 4

1 Seat base depth
2 Lumbar support and lateral guidance 5
6
4 Adjust the front/back position)
5 Adjust seat angle 8 7
6 Adjust height of seat base
7 Adjust vertical damper (soft/hard) Controls for the seat in the maximum equipment level

wheel.
First set the drivers seat, then adapt the steering wheel
to the modified seat position.
Press and hold pushbutton(9) on the drivers seat 9
console with your heel.
Release pushbutton (9) again.
The steering wheel is locked.
Driver's seat console
44
1 2
Adjusting the mirrors
1 Select side (left/right side)
2 Adjust mirror surface 5
3 Select mirror: 3
Kerb mirror/main mirror/wide-angle mirror 4
4 Switch mirror heating on/off
The check lamp in the switch lights up when the mirror
heating is turned on.
5 Briefly moving the main mirror outwards
The mirror swivels back automatically after about
30seconds.
Door module
4.2.4 Heating and ventilation
Functions on the control panel

6 Ventilate side windows 6 7 8 9 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
Controls for heating and ventilation
45
4.2.5 Braking

The check lamp comes on. 2
Releasing the parking brake 1

Pull the lever catch (2).
released position.
The check lamp goes out Parking brake in the gearshift "Parking brake" check lamp
console on the instrument panel
Switching on the engine brake

Press button (4 or 6).
Switching off the engine brake

Press button (4 or 6) again.
3
5
Retarder/Intarder

Increase braking power gradually:
Press steering column switch (3 or 5) down.
Reducing braking power gradually: 4 6

Press steering column switch (3 or 5) upwards.
The display shows the "retarder operation" symbol with

the corresponding level. Sustained-action brake lever Sustained-action brake lever in
vehicles with multifunction steering
wheel
Switching to full power:
Press key (4 or 6).
Switching off:
Hold steering column switch (3 or 5) upwards or press
key (4 or 6) again.
Retarder/Intarder level indication on the display
46
MAN BrakeMatic
BrakeMatic is switched on automatically after the ignition is 1
switched on. No check lamp in rocker button (1) comes on.
2
Switching off BrakeMatic
Press rocker button (1). MAN BrakeMatic rocker button Display showing BrakeMatic
switched on
Switching on BrakeMatic
Press rocker button (1) again. # -
The check lamp in the rocker button goes out and #
# 1
symbol (2) appears on the display.
#, 1,
MAN TipMatic DNR switch

Drive, forwards: D1 and D3 or D
(depending on version of the MAN TipMatic drive/neutral/reverse switch
DNR switch)
Neutral: N
Drive, reverse: R1
4 5 6
Manoeuvre, reverse: RM %%
7.
,
Note .%% 43.

, -
43.
, -
.%%
,$, , 7
Drive the vehicle in automatic mode if possible. 2$3
Switching between automatic and manual mode: 3

Press key(4).
In vehicles with multifunction steering wheel: Press Steering column switch in vehicles Steering column switch in vehicles
handle(6).
wheel
Upshift:
One gear: Briefly pull steering column switch (3 or 5)
towards the steering wheel.
Downshift:
One gear: Briefly press steering column switch (3 or 5)
Several gears: Push and hold the steering column
switch. Display: "Automatic" Display: "Manual", maximum
number of gears which can be
engaged
47
Gearbox
1 Toggle switch
down: Gears 1 4 and reverse 3
up: Gears 5 8
2
2 Slide switch 1
forwards: High splitter box
rearward: Splitter group low
3 ComfortShift key (only with MAN ComfortShift gearbox)
Gear display: Shift lever

4 Neutral position
5 Engaged gear
6 Gears 14 (low range) 7 8
7 Gears 58 (high range)
8 Splitter group high
9 Splitter group low
MAN ServoShift manual gearbox: 4 6 5 9

gear.
MAN ComfortShift manual gearbox: "Neutral" indication on the display "1st gear engaged" indication
on the display
gear at speeds less than 5km/h!
Depress the clutch fully for changing gear at speeds
greater than 5km/h or
Press ComfortShift key (3) until the gearshift has been
completed.
48
6 8
frame is lowered! 4
If the vehicle has a lowered frame, it must only
3 9
be moved slowly and carefully.
10
1

remote control into the holder on the console
of the driver's seat.
ECAS remote control

1 Manual lifting
2 Manual lowering
3 Memory key 1
4 Memory key 2
suspension)
9 Ride height
10 Stop key

Press key (9).
Press keys (7) and (5) again to switch off ECAS

remote control.
The associated check lamps (8), (6) go out
49
2
4.2.8 Starting and stopping the engine
3
Ignition lock
1
4 Start position
Starting the engine

necessary.
Unlock the steering.
the heating-up procedure has started and the "flame
start" check lamp (5) goes out.
engine and release the ignition key.
5
Stopping the engine
If the engine has been running under considerable load,
do not stop it immediately but let it idle briefly first. Only in vehicles with a flame start system: "flame start" check lamp on the
display
Stop the vehicle.

wing extension.
50
4.3 Breakdown assistance
4.3.1 Tilting the cab
Safety instructions
Danger! Caution!
Danger of injury during the tilting process! With an air-sprung front axle in conjunction with
The hydraulic cylinder is not suitable for 385/65 R 22.5 tyres, there is a collision between
holding the cab in any position. the entry steps and the tyres when both the air
Only tilt the cab when the vehicle is in a suspension and the cab are lowered (i.e. both air
horizontal position. springs against the block)! If the tilting procedure is
In the interests of safety, keep the tilting not cancelled, the entry steps will be damaged.
area in front of the cab clear. In a vehicle fitted with 385/65 R 22.5 tyres, only
No-one is allowed to be positioned tilt the cab if the cab air spring is pressurised.
wholly or in part between the cab and
chassis during the tilting process. Caution!
Never lean on the vehicle whilst the cab Danger of refrigerator compartment damage!
is being tilted. Air bubbles which enter the cooling circuit due to
Always tilt the cab forwards to its final tilting can impair the cooling system.
position. Once the cab has been tilted backwards, do not
switch the refrigerator compartment back on for
Warning! at least 2 hours.
The function of a pacemaker can be
severely impaired due to the EM radiation Caution!
from the engine control unit! In vehicles in the TGX and TGS series:
People who have a pacemaker fitted Components can be damaged when tilting.
must keep a distance of at least 20cm Therefore, before tilting:
from the running engine. Switch off the windscreen wipers.
The windscreen wiper arms must be in the rest
Before tilting forwards position.
Apply the parking brake. Open the front flap before tilting the cab.
Secure the vehicle with wedges to prevent it When pumping, keep enough distance between
from rolling away. the operating rod and the cab and indicator
Move the selector lever to neutral. In vehicles equipped for snowplough and
Switch off the engine. gritter operation, remove the implement (e.g.
Secure any loose objects in the cab. snowplough) before tilting.
Empty the storage box.
Switch off the auxiliary heater. Note
Empty, switch off and defrost the refrigerator In vehicles in the TGX and TGS series:
compartment. Release the lock on the front flap in the cab,
Close the doors. open the front flap.
Remove the rod and actuator rod for the
changeover valve for tilting the cab under the
front flap.
51
1
3
Tilting the cab hydraulically 2

The changeover valve for tilting the cab is fitted behind the
rear wall of the cab.
Open the cover in the cab entry (1).
Move the lever (2) of the changeover valve upwards to
the stop.
Place the wheel nut spanner (tool kit of TGA) or wheel
nut spanner with angled end (tool kit of TGX, TGS) onto
the hexagon profile (3), insert the actuator rod (tool kit)
and pump (4). Cover in cab entry Reversing valve
The cab locks release the cab and it tilts forwards.
Continue pumping until the cab has reached its end
position
The cab lock can be heard to engage.
4
Lowering the cab hydraulically
Danger!
The cab suddenly drops into the cab lock over the
last 10 to 15cm!
Danger!
If the cab is not locked, it can tilt forwards on
braking and cause serious accidents!
Always lower the cab as far as the limit position Tilting the cab
and make sure it is engaged.
Move the lever of the changeover valve (2) downwards

as far as the stop.
Place the wheel nut spanner (TGA) or wheel nut
spanner with angled end (TGX, TGS) onto the hexagon
profile, insert the actuator rod (tool kit) and pump.
Continue pumping until the cab moves down
automatically and you hear the cab locks engage.
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
Tilting the cab electrically

Press the bottom of the rocker switch.
Open the cover in the cab entry (1)
Move the lever (3) up as far as the stop.
Solenoid button with rubber cap:

Press button (4) until the cab has reached the end "Cab tilt mechanism" "Cab tilt mechanism"
rocker button TGX, TGS rocker button TGA
position
Solenoid button without rubber cap:

Touch button (5) with a metallic object (e.g. vehicle key)
1
until the cab has reached the end position.
Hydraulic tilting is possible if the electrical system has

failed. 2
Lowering the cab electrically

Move the lever of the changeover valve (3) downwards
as far as the stop.
Solenoid button with rubber cap:

Press the button until the cab lowers automatically and
can be heard to engage in the cab lock.
Cover and solenoid button in cab entry
Solenoid button without rubber cap:
Touch the button with a metallic object until the cab
lowers automatically and can be heard to engage in the
4
cab locks.
You will hear the pump motor running heavily after the 3
cab has engaged.
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 Solenoid button without rubber cap
must go out.
Also, the "STOP" symbol with the "LOCK CAB"
message must go out on the driver's display.
53
4.3.2 Checking service products

1
Checking the engine oil level
The vehicle must be parked on a level surface for
checking the oil level, and the engine must be cold or
have been stopped for at least 15min.
Check the oil level using the driver's display
(Operating data Engine data Oil level) or
with the cab tilted, use the dipstick (1).
Topping up engine oil

Release the lock in the cab, open the front flap. Dipstick
Top up the missing oil through the filler pipe (2).
Caution!
Too much oil is damaging for the engine and the
environment!
Do not exceed the maximum oil level.
2
Checking coolant
The vehicle must be on a level surface for checking the 3
coolant level.
Check the coolant level using the driver's display
(Operating data Engine data Coolant level) or
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 pres-
sure and at a high temperature.
Only open the screw cap when the engine has
cooled down, and only open by 2 3 turns at
first in order to allow surplus pressure to escape.
Only then open fully.
Caution!
Excessive temperature differentials can damage the
engine!
Do not fill cold coolant if there has been a large
coolant loss and the engine is hot.
Wait for the engine to cool down
54
Checking the steering hydraulic fluid level

The vehicle must be parked on a level surface in order
for the steering hydraulic fluid level to be checked.
1
Switch off the engine.
Tilt the cab.
Check the level at dipstick (1).
Fluid level with the engine stopped: 2
Top mark on the dipstick
Top up missing fluid via the measuring opening (2).

Clutch actuation expansion tank
Checking the clutch hydraulic fluid level
The vehicle must be parked on a level surface in order
for the clutch hydraulic fluid level to be checked.
3
Switch off the engine
Open the front flap
Check the level in the expansion tank (4)
The fluid level in the expansion tank must be between 4
the MIN and MAX marks.
If the level is too low, top up the fluid to the correct level
through the filler hole (3).
Expansion tank for clutch fluid
55
4.3.3 Bleeding the fuel system

Tilt the cab.
Unscrew the primer of the hand-operated pump.
Pump the primer until the overflow valve is heard to
open.
Press the primer down and screw it on tightly.
Lower the cab.
4.3.4 Changing a wheel
Safety instructions Pump tappet
Danger!
Inadequate support can allow the vehicle to move Jacking points
downwards uncontrollably and cause severe
injuries!
away.
Only set up the jack on level, firm ground.
Only use the jack for short jobs.
Use stands for longer jobs.
Warning!
Other vehicles represent a sustained and
increased risk of accidents at the breakdown site!
Always wear a high visibility tabard when
changing a wheel.
Secure the vehicle and the breakdown site
in accordance with the applicable statutory
Front axle with leaf-spring suspension, non-driven
regulations.
Warning!
On all vehicles with air suspension: Adjustment of
the electronically controlled air suspension (ECAS)
can cause the jack to slip!
Switch off the ignition.
Wait for the ECAS system to adjust
Switch off the battery master switch (optional).
56
Jacking points
Front axle with air suspension, non-driven Tandem rear axle with leaf-spring suspension
Front axle, driven Rear axle with air suspension
Rear axle with leaf-spring suspension Automatically lifting trailing/leading axle
57
Changing a wheel
Always use centring sleeves when removing and fitting
a wheel.
Centring sleeve for steel rim:
Parts no. 80.99619-0067, see also appendix 6.1
Centring sleeve for alloy rim:
Parts no. 81.9302121-0089, see also appendix 6.1
Tightening torques for wheel nuts

8-hole rim (M20x1.5): 475 25Nm
10-hole rim (M22x1.5): 575 25Nm
TPM tyre pressure monitoring system (optional):

Have the wheel modules of the tyre pressure monitoring
system fitted in a MAN Service workshop.
58
4.3.5 Tow-starting
Tow-starting is always the last alternative because of the
risk involved and the strain imposed on the vehicle and
driver. Without doubt, always prefer jump starting,
see chapter 2.2
It is not possible to tow-start vehicles with:

Damage to the engine, gearbox, transfer case,
axle and steering
Automatic gearbox
MAN TipMatic gearbox (AS-Tronic)
Inadequate brake pressure
Batteries not installed
Batteries only partially charged
Safety instructions
Warning! Caution!
If the spring-loaded brake cylinders have been If the vehicle is tow-started too quickly, the engine
released by external compressed air supply or may be damaged when the clutch is engaged.
mechanically ( see chapter 4.4.2 for information): Tow-starting speed < 30km/h
The reservoir brake pressure is not sufficient to Do not tow-start in reverse.
ensure correct braking!
Never tow-start if the spring-actuated brake Tow-starting
has been released according to chapter 4.4.2. Turn the key to the "ignition on" position.
Disengage the clutch
Warning!
There is no steering support if the engine is Engage a high gear (5 8).
stopped! Considerable effort is required at the
steering wheel. Tow-start the vehicle until an adequate speed has been
Only tow-start on a straight line. reached.
Do not tow-start in reverse. Slowly engage the clutch and press the accelerator until
Only tow-start with a towing bar, do not the engine starts.
use a cable. For fitting the towing bar see
chapter4.4.3. If the engine does not start within 15 seconds:
Disengage the clutch
With a manual gearbox: Shift the gearbox to neutral.
Tow-start the vehicle with the high range Stop.
engaged. Repeat the tow-starting procedure one more time at
most.
59
4.4 Towing
4.4.1 Notes
Safety instructions
Warning! Caution!
Significant risk of accidents due to lack of braking Danger of gearbox damage! Adequate lubrication
effort!The gross combination weight can exceed of the gearbox is not guaranteed when towing. As
40t. The brake system of the towing vehicle a result, the gearbox is not allowed to be driven by
cannot exert adequate braking effort for the entire the wheels during towing.
towed combination. The following applies to conventional rear-axle
Before towing, check the braking effort of the drive:
broken-down vehicle. Before towing with a towing bar or with the
front lifted, always disconnect the driveline,
If the brake system of the broken-down vehicle is see chapter 3.
functional:
When towing with the vehicle lifted, connect The following applies to all-wheel drive:
the pneumatic brake system of the broken- Disengage all-wheel drive if possible.
down vehicle to the towing vehicle (automatic Disconnect the driveline before towing,
joint braking see chapter 4.4.6). see chapter 3.
When towing with a towing bar, leave the
engine of the towed vehicle running. The towed
vehicle must have a driver to steer and brake
the vehicle.
If the brake system of the broken-down vehicle is

not functioning:
Maximum towing speed: 10km/h
Only tow the vehicle as far as the nearest
suitable specialist workshop.
60
4.4 Towing
Towing with a damaged engine Towing vehicles with damaged axles

If the engine is damaged, the brake system is no longer In the event of axle damage, make sure the damaged axle
supplied with sufficient compressed air. The existing does not have any contact with the ground during towing.
brake pressure may dissipate due to leakages. This can
cause the spring-loaded accumulators to apply the brakes In case of front axle damage:
uncontrollably during driving. Tow with the front lifted, see chapter 4.4.4
To release the spring-loaded accumulators: In case of rear axle damage:

Supply compressed air via filler connection "IN", Tow with the rear lifted, see chapter 4.4.5
see chapter 4.4.2. In vehicles with electronic air
management system (ECAM), release the spring-loaded If the damaged axle cannot be lifted during towing:
accumulators mechanically. Remove the axle shafts on the axle in question or
load onto another vehicle.
To have the towed vehicle participate automatically in
braking:
Connect the pneumatic brake system of the towed
vehicle to the towing vehicle, see chapter 4.4.6.
If the power steering fails, the effort required at the steering

wheel is very great. Without power steering:
Only tow over short distances at highly reduced speed,
or tow with the front end lifted, see chapter 4.4.4.
Do not steer when stationary, otherwise the steering
system might be damaged.
In all-wheel drive vehicles with mechanical all-wheel drive:

Engage the on-road range of the transfer case.
In all-wheel drive vehicles with MAN HydroDrive:

Disengage front axle drive.
61
4.4 Towing
4.4.2 Releasing spring-loaded accumulators 9RUUDWVGUXFN

]XJHULQJ
Function of the spring-loaded brake cylinders

The spring brake cylinders are applied when the reservoir 1
pressure in the parking brake circuit has dropped below the
release pressure of the spring-loaded diaphragm cylinder
2 3 4
(approx. 6.0 bar).
Indications on the instrument panel:

The driver's display shows the "STOP" signal (1) with
the message "AIR PRESSURE TOO LOW".
The "brake system" (2) and "parking brake" (3) check Displays on the instrument panel when spring-loaded brake cylinders are
activated (e.g.: TGX)
lamps light up.
The red central warning light (4) flashes.
An acoustic warning signal sounds.
Note
In case of a breakdown, the spring-loaded brake
cylinders can be released pneumatically or
mechanically.
Safety instructions
Warning! When towing with a towing bar, leave the

Danger of a serious traffic accident due to lack of engine of the towed vehicle running and have
braking effort or malfunctions of the brake system! the towed vehicle participate in braking.
After emergency release of the spring-loaded Comply with additional instructions in the
brake cylinders, the reservoir pressure in brake following chapters:
circuits 1 and 2 may not be sufficient to guarantee 4.4.3 (towing bar) or
correct braking; under certain circumstances, 4.4.4 (front lifted) or
there is no brake pressure at all available. A slow 4.4.5 (rear lifted) as well as chapter
pressure drop in brake circuit 3 can result in the 4.4.6 (connect pneumatic brake systems).
spring-loaded accumulators applying the brakes
uncontrollably during towing. Warning!
To ensure that the brake system on the towed Danger of injury if the vehicle is not secured!
vehicle is functioning: Secure the vehicle to prevent it from rolling
Make sure there is adequate reservoir pressure away before releasing the spring brake
in the spring-loaded brake circuit by supplying cylinder.
from an external source (towing vehicle),
see the next chapter "Releasing spring-
loaded accumulators pneumatically".
62
4.4 Towing
Releasing spring-loaded accumulators pneumatically 1

During pneumatic release, compressed air is supplied from
another vehicle to the pneumatic brake system.
Filling connections:
At the test connections under the battery box. The filler
connection (1) is indicated with "IN"
or
Behind the front flap in the area of the pedal brake
valve(2)
"IN" filler connection at the test connections (e.g.: TGX)
Necessary supply pressure:
Minimum pressure: 7.5bar
Maximum pressure: 12.5bar
Supplying compressed air and releasing the spring-loaded

accumulators: 4
Prevent the vehicle from rolling away
Switch on the ignition.
Set the parking brake lever to the released position.
Remove the cap on the filler connection.
Connect the inflating hose from the other vehicle to the
filler connection.
Charge the compressed-air system.
If there is adequate reservoir pressure in brake circuit 3 Filler connection behind the front flap (e.g.: TGX)
(approx. 5.4 to 5.8 bar):
The "STOP" symbol (3), the "brake system" (4) and
"parking brake" (5) check lamps as well as the central
warning light (6) go out.
The parking brake is now released. 9RUUDWVGUXFN
]XJHULQJ
Note
If the vehicle is towed when raised:
3
Continue the compressed air supply during
towing as well.
4 5 6
Displays on the instrument panel when spring-loaded brake cylinders are

activated (e.g.: TGX)
63
4.4 Towing
Releasing spring-loaded accumulators using the

mechanical method
Warning!
Danger of accidents due to failure of the parking
brake!
The parking brake does not function after having
been mechanically released, even if the compressed
air system is charged. In the case of the mechanical
spring actuator emergency release device, there is
no indication that the emergency release device has
been released mechanically. The indication remains Spring-loaded accumulator variant Spring-loaded accumulator variant
NG3: Feature of the clamping band NG5: Feature of the flanging
on the driver's display, the "parking brake" check
lamp and the red central warning light in the panel of
check lamps and warning lights continue to be lit.
Only release the spring-loaded accumulators
mechanically if pneumatic release is not possible.
Warning!
Danger of injury due to trapping! 1
It is essential to comply with the maximum
release torque of the installed spring-loaded
accumulators variant (NG3 or NG5)!
Caution!
Never use impact drivers to unscrew, screw
in or tighten the release spindle. Comply with
the maximum tightening torque of the installed
spring-loaded accumulator variant (NG3 or NG5)! Unscrewed release spindle on the spring-loaded brake cylinder NG3
Releasing the spring-loaded accumulator in version NG3:

Secure the vehicle to prevent it from rolling away.
Unscrew the release spindle (1) fully, approx. 60mm (with
2
leading or trailing axle approx. 35mm), until the braking
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. Inoperative spring-loaded brake cylinder NG3 with indicator sticking out (in
air-sprung three-axle and four-axle vehicle)
64
4.4 Towing
After repairs with the parking brake released:

Charge the brake system until the shut-off pressure is
reached.
Clean and grease the release spindle.
Reinsert the release spindle as far as the stop and
tighten it.
Tightening torque of the release spindle: 30 to 70 Nm
The indicator is withdrawn again.
Have the brake system checked in a MAN Service Operational spring-loaded brake cylinder NG3 with retracted indicator (in
workshop.
Releasing the spring-loaded accumulator in version NG5:

Unscrew the release spindle (1) until the braking effect 1
is cancelled (max. 38 mm).
Release torque of the release spindle: max. 45 Nm
The parking brake is now released and does not
function.
panel remain lit.
PD[
In three and four-axle vehicles with air suspension: PP
Indicator projects from the spring-loaded accumulator
housing.
Inoperative spring-loaded brake cylinder NG5 with unscrewed release
spindle
reached.
tighten it.
Tightening torque of the release spindle: 30 to 70 Nm
In three and four-axle vehicles with air suspension. The
indicator is pulled back again.
Have the brake system checked in a MAN Service
workshop.
Operational spring-loaded brake cylinder NG5 with tightened release

spindle
65
4.4 Towing
4.4.3 Towing with a towing bar
Warning! Caution!
Danger of accidents! In vehicles with air suspension (ECAS):
Leave the engine of the towed vehicle running. The air suspension system can be damaged
The towed vehicle must have a driver to steer if the suspension fails due to lack of reservoir
and brake the vehicle. pressure in the brake system.
Only tow with a towing bar, cables are only to Ensure adequate reservoir pressure in the
be used for recovery, see chapter 4.5. brake system by external supply from the
Do not exceed the permitted pulling force, see towing vehicle, see chapter 4.4.2 "Releasing
below. spring-loaded accumulators pneumatically".
Warning! If the air suspension system cannot be activated

Danger of accidents due to uncontrolled driving even by an external compressed air supply:
behaviour of the towing vehicle if the towed vehicle Only tow the vehicle slowly and with increased
is not also steered appropriately! caution.
Only use a towing bar to tow a vehicle which
has a functioning steering system. If the
steering system is damaged, lift the vehicle at
the front, see chapter 4.4.4.
In the event of engine damage, the power steering

will fail and the necessary steering effort is very
great. In case of power steering failure:
Only tow at highly reduced speed or with the
front lifted, see chapter 4.4.4.
Caution!
Towing the vehicle when loading can cause
additional damage!
Unload the towed vehicle before attaching the
towing bar.
If unloading is not possible, tow with increased
caution.
66
4.4 Towing
Vehicles with plastic bumpers
Towing eyes:
At least one towing eye must be fitted to the bumper for
towing. The maximum permitted pulling force at the towing
eye during straight-ahead and angled towing can be found
in the table in the appendix ( 6.3).
It is essential to avoid towing at an angle of more
than15.
We recommend using two towing eyes. Two towing eyes Remove the cover for the fastening thread on the bumper
(e.g.: TGX; TGS and TGA accordingly)
enable twice the pulling force to be transmitted, and the
towed vehicle will run behind the towing vehicle without
misalignment.
There are two fastening threads for towing eyes in the
bumper. A towing eye is supplied with each vehicle from
the factory. It is located in the storage locker on the right, or
in the vehicle's tool kit in vehicles without storage lockers
inside the vehicle.
Always carry two extra towing eyes to the breakdown
site (parts no. 81.42015.6025, see also appendix 6.1).
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 heavy-
range vehicles (parts no. 81.42015.6028, see also
appendix6.1). If necessary, clean the fastening thread with thread cleaner
The maximum permitted speed when towing with the
towing bar is 62km/h.
Attaching the towing equipment:

Remove the cover for the fastening thread in the
bumper, e.g. using a flat-blade screwdriver.
Remove any corrosion and dirt from the fastening
thread using thread cleaner (parts no. 08.42914.0509,
see also appendix 6.1).
Screw in the towing eye until the stop. T hen unscrew it
far enough for a towing bar to be hooked in (maximum
1/2 turn).
Recommendation: Attach the shunting coupling.
Installing the towing eye
67
4.4 Towing
Towing:
Precondition: The driveline is disconnected
( see chapter3).
Switch on the battery master switch.
Turn the ignition key to position (2) and unlock the
steering lock.
Turn the ignition key to the driving position (3).
Leave the engine of the towed vehicle running if
possible.
The maximum permitted pulling forces at the front
crossmember during straight-ahead and angled towing Towing eyes screwed in at both sides
can be found in the table in appendix6.3.
Steer and brake the towed vehicle as well during towing.
After towing:
Unscrew the towing eyes.
Grease the screw-in thread in the bumper.
Even force application via MAN shunting coupling
2
3
Turning the ignition key to the driving position
68
4.4 Towing
Vehicles with steel bumper and tow bar hitch
Coupling jaw:
The tow bar hitch is a manoeuvring device. The maximum
permitted pulling force at the tow bar hitch during straight-
ahead and angled towing can be found in the table in the
appendix ( 6.3).
than15.
Attaching the towing equipment:

In TGX and TGS: Fold down the number plate Steel bumper and tow bar hitch (e.g.: TGS; TGX and TGA similar
Swivel the lever on the coupling pin approx. 45
forwards, pull the coupling pin out upwards.
Hook in the towing bar and close the coupling pin.
Make sure the lever engages securely.
Towing:
Precondition: The driveline is disconnected
( see chapter3).
Switch on the battery master switch.
steering lock.
possible.
Do not exceed the maximum pulling force. Pulling out the coupling pin
2
3
Turning the ignition key to the driving position
69
4.4 Towing
4.4.4 Towing with the front of the vehicle lifted
Warning! Warning!
An incorrectly lifted vehicle can cause a severe Dangers of accidents due to inadequate brake
traffic accident during towing! In any event, force and malfunctions of the ABS and ASR!
damage to the vehicle will be unavoidable. Connect the rear axle and trailer brake circuit
Only lift the front axle using suitable of the towed vehicle to the towing vehicle.
equipment, and make sure it is evenly lifted. Ensure the reservoir pressure is adequate by
In case of vehicles which have been involved in external supply ( see chapter 4.4.6.
an accident, check the connections between When the vehicle is lifted, turn the ignition key
the frame components as well as between the to position "0" and withdraw it, to deactivate
frame and front axle. ABS and ASR.
In vehicles with a plastic bumper and towing eyes: Caution!

If the towing eyes are used for lifting, use both Lifting and towing a laden vehicle can cause
towing eyes. Never lift the vehicle with a single additional damage!
eye. Unload the towed vehicle before lifting.
Secure the underbody lift during driving to
prevent it from springing out. Use lockable If unloading is not possible:
retaining yokes (e.g. from Wolfgang Brechtel Take additional measures according to the
GmbH, see also appendix 6.1). information in the following chapters.
Only lift and tow with increased caution.
In vehicles with a steel bumper and tow bar hitch:
Never lift at the tow bar hitch.
Either lift at the wheels with a wheel gripper or
at the axle with axle yokes.
70
4.4 Towing
Overview: Towing with the front of the vehicle lifted
Vehicle concept Laden Towing when lifted at Towing when lifted at Towing when lifted
vehicle the towing eyes1) the front wheels with axle yokes
no +
no +
yes +
no +
yes + +2)
no +
yes +
++ = Only possibility + = Preferred method = 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
4.4 Towing
Lifting at the towing eyes
Preconditions:
Driveline is disconnected ( see chapter 3).
Vehicle is unloaded.
Hooking in an underbody lift:

Remove the cover for the fastening thread in the
bumper, e.g. using a flat-blade screwdriver.
Remove any corrosion and dirt from the fastening
thread with thread cleaner (parts no. 08.42914.0509,
see also appendix 6.1). Example: Semitrailer tractor with semitrailer, lifted at the towing eyes
Screw in the towing eyes as far as the stop. T hen
unscrew them until the lockable axle yokes of the
underbody lift can be hooked in (max. 1/2 turn).
It is essential to prevent the connection between the
holding yokes and the towing eyes from springing out.
Use lockable holding yokes for this.
Removing the cover for the fasten- If necessary, clean the fastening
ing thread on the bumper thread with thread cleaner
Screwing in the towing eyes
72
4.4 Towing
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.
Information for a laden vehicle
Note Lifting at both towing eyes use lockable holding yokes

If a laden vehicle must be lifted:
Only lift the laden vehicle for a short time if at all
possible. In case of overloading, the towing eyes
will deform before further damage occurs on the
vehicle.
Towing a vehicle which is lifted at the towing eyes
is permitted as long as the towing eyes do not
deform.
Make sure the rear end does not bottom out
73
4.4 Towing
Lifting the vehicle at its wheels
Warning!
Danger of accident due to malfunctions of ABS
and ASR!
Turn the ignition key to position "0" and pull it
out to deactivate ABS and ASR.
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:
Preparatory work on vehicles with reduced ground

clearance:
Lift the vehicle at the towing eyes and place it on
ramps(1).
Using wheel grippers or a wheel lift unit:

Move the wheel grippers or wheel lift unit under the
vehicle and adjust to the track width of the vehicle. 1
Lift the vehicle.
Secure both wheels to the wheel lift unit using straps.
Additionally secure the cross head to the front axle with Vehicle with low ground clearance on ramps
chains.
Lashing the wheels to the wheel lift unit using straps
74
4.4 Towing
Four-axle vehicles:
If the vehicle is unladen: Lift until the wheels of the front
axle are no longer in contact with the ground.
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.
Vehicles with air suspension
Caution!
In vehicles with an air-sprung front axle, the Both front axles have no contact with the ground; only permitted if the
vehicle is unladen
wheel lift unit or wheel grippers can damage the
longitudinal links!
When lifting, check whether components come
near the longitudinal link, it is essential to avoid
any collision.
If there is a risk of collision between the wheel lift

unit or wheel gripper and the longitudinal links:
Lift the vehicle with axle forks.
In vehicles with an air-sprung front axle, the wheel grippers

can strike against the longitudinal links
75
4.4 Towing
Lifting vehicles with air suspension using axle forks
Warning!
and ASR!
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)
Lift the vehicle at the towing eyes and place it on ramps,
or lift the front axle with a lifting cushion.

Move the underbody lift under the vehicle and attach
axle forks to the front axle.
Lift the vehicle carefully. When doing this, make sure
that the steering linkage, springs, anti-roll bars, hoses
and cables are not damaged.
Secure the front axle with chains or straps on the
underbody lift.
Four-axle vehicles:
If the vehicle is unladen: Lift until the wheels of the front
axle are no longer in contact with the ground.
If the vehicle is laden: Carry out further measures
according to page 78. Lifting the front wheels with a lifting cushion
Hooking axle forks onto the front axle and securing with chains
76
4.4 Towing
Lifting vehicles with leaf suspension using axle forks
Warning!
and ASR!
Preconditions:
Preliminary work if the ground clearance is inadequate: Towing a four-axle vehicle, front lifted with axle forks
Lift the vehicle at the towing eyes and place it on ramps,
or lift the front axle with a lifting cushion.

Move the underbody lift under the vehicle.
Either grip the axle beam with axle forks or
use suitable holding devices on the spring shackles of
the leaf springs (1 or 2) for gripping.
that the steering linkage, anti-roll bars, hoses and
cables are not damaged.
Secure the front axle or frame onto the underbody lift
using chains or straps.
Four-axle vehicles:
If the vehicle is unladen: Lift until the wheels of the front Hooking axle forks onto the front axle and securing with chains
axle are no longer in contact with the ground. The front
axle wheels must have adequate ground clearance
during towing, even when the ground is uneven. 2
If the vehicle is laden: Carry out further measures
according to page 78.
Force application points when lifting at the spring shackles
77
4.4 Towing
Lifting laden four-axle vehicles/

laden vehicles with two front axles 1
Set the steering axles to straight ahead.
Remove the drag rod (1) at the second front axle.
Move the underbody lift under the vehicle and attach
axle forks to the front axle.
Clamp the first front axle onto the axle beam of the
second front axle (3). This distributes the pulling forces
between both axles.
Clamp the first front axle forwards against the frame
(2). This means the braking forces are transferred to the Drag rod on the second front axle (e.g. TGA)
axle and frame.
Remove the front wheels ( see chapter 4.3.4).
Lower the vehicle until the wheels of the second front 2
axle are in contact with the ground and the axle also
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
4.4 Towing
4.4.5 Towing with the rear of the vehicle raised
Warning!
An incorrectly lifted vehicle can cause a severe
traffic accident during towing! In any event,
damage to the vehicle will be unavoidable.
Only lift the front axle using suitable
equipment, and make sure it is evenly lifted.
In case of vehicles which have been involved in
an accident, check the connections between
the frame components as well as between the
frame and front axle. Securing the steering wheel
In vehicles with two rear axles:
Lift the vehicle until the wheels of both rear
axles are no longer in contact with the ground.
The rear wheels must retain adequate ground
clearance during towing, even when the
ground is uneven.
Warning!
If the front axle is not secured, it could become
involved in the steering procedure and cause a
serious traffic accident!
Set the front wheels to the straight-ahead
position and let the steering lock engage.
It is essential to secure the steering wheel with
straps as well. The steering lock alone cannot
withstand the forces.
Warning!
Dangers of accidents due to inadequate brake
force and malfunctions of the ABS and ASR!
Connect the front axle brake circuit of the
towed vehicle to the towing vehicle. Ensure that
there is reservoir pressure by external supply;
see chapter 4.4.6.
out in order to deactivate ABS and ASR.
79
4.4 Towing
Caution!
Lifting and towing a laden vehicle can cause
additional damage!
Unload the towed vehicle before lifting.
If unloading is not possible:

Take additional measures according to the
information in the following chapters.
Never lift a laden vehicle by a trailing axle. Comply
with the permitted axle load.
Only lift and tow with increased caution.
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.
Only lift vehicles with two steered front axles
from the front.
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
4.4 Towing
Lifting and towing at the rear crossmember
Warning!
and ASR!
Preliminary work:
Unload the vehicle.
In vehicles with all-wheel drive: Remove the driveshaft
to the front axle see chapter3. Cross head attached to the rear crossmember using axle forks and chains
As far as necessary, disconnect lines, compressed
air tanks, etc. and secure them to stop them dropping
down whilst driving.
Lifting the vehicle:

Connect the cross head of the underbody lift with the
rear crossmember.
Lift the vehicle.
Lift vehicles with several rear axles until all rear wheels
no longer have contact with the ground.
Note
Comply with the permitted axle load.
Hooking a safety chain onto the rear crossmember
81
4.4 Towing
Lifting a vehicle with leaf suspension at the wheels
Warning!
and ASR!
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 Fastening the wheels to the wheel grippers using straps
permitted.
Preliminary work:
to the front axle, see chapter 3.2.
In addition in vehicles with two rear axles:

If only lifting at one rear axle:
Unload the vehicle.
Tie up the front rear axle up to the frame with straps
or chains. The axle should not move to the end of its
suspension travel during towing, in order to prevent
the cardan shaft being pulled apart at the length
compensation point.
Pay attention to hoses and lines when doing this, do not
bump the frame. Lifting a vehicle with a double rear-axle assembly until the rear wheels are
not longer in contact with the ground
Hooking in wheel grippers:

Move wheel grippers under the vehicle and set them to
the track width of the vehicle.
Lift the vehicle.
Secure both wheels on the wheel grippers using straps.
Lift vehicles with rear axles until all rear wheels are no
longer in contact with the ground.
82
4.4 Towing
Lifting a vehicle with air suspension at the wheels
Warning!
and ASR!
Preliminary work:
to the front axle, see chapter 3.2. Towing a three-axle vehicle with air suspension, lifted at the rear wheels
In addition in vehicles with two rear axles:

If lifting at a trailing axle: Unload the vehicle.
Tie the front rear axle onto the frame using straps
1
or chains (1). The axle should not move along its
suspension travel during the towing, in order to avoid
damaging the air bags.
Pay attention to hoses and lines when doing this, do not
bump the frame.

Caution!
There is a risk of collision between the cross head Tying up the front axle (note: the vehicle has been lifted for the photograph;
only tie up the axle if the vehicle is lowered)
and air vessel, depending on the ground clearance
of the vehicle and the installation position of the
air vessels! The cross head can also open the vent
valves of the air vessels.
When lifting the underbody lift, make sure
there is an adequate distance between the
cross head (3) and air vessel (2). It is essential
to avoid collision with or opening of the vent
valves. 2
Lift the underbody lift slowly.

Lift vehicles with two rear axles until all rear wheels are
no longer in contact with the ground. 3
The cross head of the underbody lift is not allowed to open the vent valves
of the air vessels
83
4.4 Towing
Lifting a vehicle with axle forks

If the vehicle cannot be lifted at its wheels, e.g. after an
accident involving axle damage:
Lift the vehicle with axle forks at the rear axle beam.
Preliminary work: 1
Unload the vehicle.

to the front axle, see chapter 3.
Remove the anti-roll bar (1).
In addition in vehicles with two rear axles and air Removing the anti-roll bar before lifting with the axle forks
suspension:
Tie up the front of the two rear axles.
Do not lift at a trailing or leading axle.
In addition with vehicles with low ground clearance:

Lift the vehicle with a lifting cushion at the rear frame
crossmember, or pull the vehicle onto ramps.

Move the underbody lift under the vehicle and hook the
axle forks onto the rear axle beam.
that springs, hoses and cables are not damaged.
Secure the rear axle on the underbody lift with chains or
straps.
Lift vehicles with two rear axles until all rear wheels are
no longer in contact with the ground.
84
4.4 Towing
4.4.6 Connecting pneumatic brake systems
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.
Supply brake pressure to the towed vehicle
using a pressure control device.
At the start of the towing procedure, observe
the braking behaviour of the towed vehicle
carefully.
Set the brake force on the towed vehicle as
required using the pressure control device.
When towing with the vehicle lifted, always set
the ignition key to "0" in order to deactivate
ABS/ASR.
85
4.4 Towing
Connecting pneumatic brake systems 1
2
Warning!
Danger of injury by compressed air! The pedal
brake valve is under high pressure when the brake
pedal in the cab is pressed.
Never press the brake pedal if any work is
going on in the area of the pedal brake valve.
Release the lock in the cab and open the front flap.
Set the pressure control valve to 5.5 bar.
Open connection 21 on the pedal brake valve (1). Connections 21 and 22 on the pedal brake valve
Open connection 22 on the pedal brake valve (2).
Connect lines 21 and 22 via a T-piece (3) and via the
pressure control device to the yellow trailer brake
connection in the towing vehicle.
Address for obtaining the pressure control adapter kit
see appendix 6.1
Establish the brake reservoir pressure supply,

see next chapter. 3
Warning!
Danger of accidents due to unbraked trailer!
In the case of tractor/trailer combinations,
always use the "Connecting pneumatic brake
systems" connection diagram.
Connect the brake circuit for the tractor vehicle and trailer or semitrailer via
a T-piece and connect to the brake connections of the towing vehicle via a
pressure control device.
86
4.4 Towing
Supplying the brake reservoir pressure from an

external source 1
Filling connections:
At the test connections, under the battery box; the filling
connection (1) is identified with "IN"
or 2 3
Behind the front flap in the area of the pedal brake

valve(4)
Supplying compressed air:

Remove the cap on the filler connection.
Connect the inflating hose from the other vehicle to the "IN" filler connection on the test connections
filler connection.
Required supply pressure:
If it is not possible to establish an adequate brake reservoir

pressure via the filler connection (e.g. if there is a defect
in the line between the filler connection and four-circuit
protection valve):
Release the spring-loaded brake cylinder mechanically,
see chapter 4.4.2
Fill brake circuit 21 (front axle/trailer) via test
connection21(2).
Fill brake circuit 22 (rear axle) via test connection 22(3).
Limit the supply pressure to 6.5 bar. Adhesive plate for test connections on the battery box
If the supply pressure is higher, there is a risk of
permanent air loss via the four-circuit protection valve,
and a defective line.
After towing 4
Warning!
Significant risk of accidents if the brake system if
faulty!
Immediately after disconnecting the pneumatic
brake system: Connect line 21 (or 22) correctly
to the pedal brake valve.
Before taking the vehicle back into operation:
Have the entire brake system examined in a
MAN Service workshop. Filler connection behind the front flap
87
4.5 Recovery
4.5.1 Notes
Comply with the following rules in order to recover a vehicle
which has been involved in an accident as safely and with
as little damage as possible:
Stabilising the vehicle

If possible, use lifting cushions to right and stabilise a
tipped-over vehicle (e.g. on an embankment) before
lifting it.
Lifting cushions can slip during righting, and jump out at Righting the vehicle with lifting cushions (e.g.: TGA)
high speed.
Secure lifting cushions to prevent them jumping out.
If possible, vacate the vicinity of the inflated lifting
cushion.
Distributing forces evenly

Applying force at a few points leads to distortions and
excessive strain.
Use as many points as possible, distributed evenly, for
applying force.
Danger of frame distortion or cracking.

Avoid applying force at one side only.
Avoid point loads and peak stresses:

Use straps which are as wide as possible. Example: Righting (applying torque) with several lifting cushions on the
driver's side, horizontal force application via wire cables at two attachment
Only use the trailer tow hitch for manoeuvring on a
points, vertical force application and stabilization via straps at four
consolidated road. Secure pulling straps to the rear attachment points
crossmember in order to pull the vehicle backwards.
Use load equalisation rollers in order to encourage even
pulling.
88
4.5 Recovery
Reducing loadings
Ideally, the vehicle should be unloaded before recovery.
Only recover a laden vehicle:
In an emergency or
if unloading is not technically feasible (e.g. cement
mixer) or
inadvisable (e.g. refrigerated vehicle)
When recovering a laden vehicle, ensure that the force

is distributed over a particularly wide area.
Correct: Force application evenly distributed over several points,
no obtuse angles at the pulling straps (e.g.: TGS)
Obtuse angles significantly increase the tensile force in
the straps, as well as the load on the force application
points.
The pulling straps should form a triangle with the most
acute angle possible, and with sides of even length. )*
)6!!)*
)6 )6
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
4.5 Recovery
Pulling the vehicle:

Avoid pulling at an angle
The tensile force required increases significantly if
pulling away from the lengthways direction of the )

)
vehicle.
) )
) ) )!)
Avoiding other damage
Do not damage frame add-ons, lines, cables or hoses
on the vehicle.
Select the most suitable components on the vehicle for
applying force, see chapter 4.5.2.
Avoid force application via safety components.
If this is not possible: Correct: Wrong:

When pulling straight ahead, the The angled pull means that too
The affected safety components must be checked by a
pulling force is no greater than much pulling force has to be
MAN Service workshop. List of safety components absolutely necessary. applied.
see appendix 6.2.
Duties of care of the operating personnel

The variety and unpredictability of possible recovery
situations means it is impossible to consider all
eventualities here. Qualified and experienced recovery
personnel are required for safe and successful recovery
operations. The recovery personnel are responsible for
deciding on the ground regarding what measures and tools
are suitable. The instructions and information in this guide
are only intended as additional information.
90
4.5 Recovery
4.5.2 Suitable force application points
Force application points for all series

During recovery, always apply the forces to the vehicle
via the following points:
Spring articulation points
Rear crossmember
Front towing eyes
(only vehicles with plastic bumper)
Limited suitability: Longitudinal link block, directly on
the frame
These components do not have unlimited load capacity.

Applying force via only a few points leads to overloading,
especially when lifting the entire vehicle.
applying force.
Always avoid applying force or transmitting force via safety

components. Refer to the appendix for a list of safety
components.
The safety components also include all axle components.

The axle beams can withstand pulling forces, depending on
the axle design. See the next chapter about this.
Also unsuitable for force application:

Underride guard
Built-on parts
Axle guidance components
Tubular crossmember
91
4.5 Recovery
Examples of force application points

Towing eyes
Application: 1
In all vehicles with plastic bumpers
A towing eye is supplied with each vehicle from the factory.

It is located in the storage locker on the right, or in the
vehicle's tool kit in vehicles without storage lockers inside
the vehicle.
Recommendations:
Always carry two extra towing eyes to the breakdown Force application via MAN shunting coupling and two towing eyes
site (parts no. 81.42015.6025,
Use the shunting coupling specially designed for all
heavy series vehicles (1) (parts no. 81.42015.6028,
92
4.5 Recovery
Tow bar hitch

Application:
In vehicles with steel bumpers
Tow bar hitch on a construction site vehicle
Rear crossmember
Application:
In all vehicles
Rear crossmember on a semitrailer tractor
93
4.5 Recovery
Front axle with leaf suspension
Force application points in the area of the leaf-spring front axle (example shows one-leaf spring; similar for two and three-leaf springs)
Use e.g. in:

Semi-trailer tractors 4x2, 6x2, 6x4
Truck chassis 4x2, 6x2, 6x4
Tippers 4x2, 6x4
94
4.5 Recovery
Front axle with air suspension
Force application points in the area of the air-sprung front axle (one-leaf spring)
Use e.g. in:

Semitrailer tractors 4x2, 6x2
Truck chassis 4x2, 6x2
95
4.5 Recovery
Rear axle with leaf suspension
Force application points in the area of the leaf-sprung rear axle (example shows two-leaf spring; similar with other numbers of leaves)
Use e.g. in:

Semitrailer tractors 4x4
Tippers 4x2, 4x4
96
4.5 Recovery
Rear axle combination with trailing axle
Force application points on a rear axle combination with trailing axle
Use e.g. in:

97
4.5 Recovery
Rear axle with air suspension and X-link (four-point link)
Force application points at the rear on an air-sprung rear axle with X-link
Use e.g. in:

Truck chassis 4x2
Caution!
Axle components are unsuitable for force
application.
Never put load on the X-link.
98
4.5 Recovery
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
Wheel hub clamp on the front axle (Krause system)
Force application via wheel hubs (Bsmann system) for lifting Force application on the rear axle of the tractor vehicle (middle right) and on
the complete tractor/trailer combination the semitrailer rear axles (bottom right)
99
4.5 Recovery
4.5.3 Pulling the vehicle forwards
Vehicles with plastic bumpers 1

Attaching a tow cable:
Fit two towing eyes to the bumper.
Recommendation:
Use a shunting coupling (1)
(parts no. 81.42015.6028, see also appendix 6.1).
The shunting coupling ensures a stable connection and
even force application.
Pulling force application via MAN shunting coupling and two towing eyes
The maximum permitted pulling force at each towing
eye or when using a shunting coupling during straight-
ahead and angled towing can be found in the table in
the appendix ( 6.3).
2
than15.
Pull evenly. Avoid pulling backwards, even if the vehicle
is stuck.
Vehicles with steel bumper and tow bar hitch

Attaching a tow cable:
In TGX and TGS: Fold down the number plate
Swivel the lever (2) on the coupling pin approx. 45
forward, pull the coupling pin out upwards.
Hook in the tow cable or hook and close the coupling Construction site vehicle with tow bar hitch
pin. Make sure the lever engages securely.

Refer to the table in the appendix ( 6.3) for the
maximum permitted pulling force at the tow bar hitch
when pulling straight ahead and at an angle.
than15.
is stuck.
If the permitted pulling force is not sufficient:

Additionally pull at the stuck axle.
100
4.5 Recovery
4.5.4 Pulling the vehicle backwards
Preliminary work:
Disconnect lines, compressed air vessels, etc. as far as
necessary and secure them to prevent them falling down.
1
Attaching pulling straps:
Attach pulling straps to the connection points between
the frame longitudinal member and the rear
crossmember (1). Insert a block of wood between the
pulling straps and rear crossmember.
Attach the pulling straps at as acute an angle as possible Rear crossmember on a semitrailer tractor
to the towing vehicle. Make sure both pulling straps have
the same length, in order to avoid pulling at an angle.

Pull the vehicle straight ahead if possible.
Avoid pulling at an angle of more than 10 at all costs.
is stuck.
4.5.5 Righting the vehicle
Righting:
Distribute the force application points as widely as
possible. Example: Righting with lifting cushions and wire cables (winch),
Securing the vehicle by tensioning with straps (mobile crane)
Apply forces from as many directions as possible in
order to stabilise the vehicle.
If possible: Use lifting cushions for righting; additionally
pull with wire cables.
Apply a counterforce by pulling vertically on the wheel
hubs during righting, in order to prevent the vehicle from
suddenly tipping back. Use a suitable force application
system for wheel hubs for this purpose, reference
address see appendix 6.1.
It is essential to comply with the installation instructions
for the force application systems.
After righting:
Caution!
Danger of engine damage oil knock!
Do not attempt to start the vehicle engine.
101
4.5 Recovery
4.5.6 Lifting the vehicle

Points for lifting with lifting cushions:
Crossmember
Axle beam (in vehicles with leaf suspension)
Points for lifting with an underbody lift:

Crossmember
Wheel hubs
Spring articulation points (in vehicles with leaf
suspension)
Front towing eyes
(in vehicles with a plastic bumper) Lifting the tractor/trailer combination with two mobile cranes
Points for lifting with a jack:

see chapter 4.3.4
4.5.7 Lifting the vehicle high

Lift the vehicle with at least one mobile crane.
Use suitable force application systems for the
application of force, reference addresses
see appendix 6.1.
Attach the attachment fittings to all wheels if possible.
If necessary, clamp blocks of wood between the pulling
straps and tyres in order to avoid damaging the wings.
Pulling straps should form as acute a triangle as
possible, with sides of even length.
102
5 Series TGL and TGM
5.1 Quick reference guide
1 2 3 4 5 6 7 8
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


instructions contained therein.
Therefore, also read and comply with 17 9
theoperator's manual.
16 15 14 13 12 11 10
supplied by manufacturers of bodies and other Instrument panel in TGL and TGM (example: Baseline)
equipment.
lamps.
5.1.2 Dashboard
Baseline 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
11 Call up and use the Vehicle menu
12 Reservoir pressure in brake circuit I
13 Differential locks
15 Set the instrument lighting
16 Select the language for the display
In Baseline L version: Changeover between pressure
display in brake circuits I and II, fuel level
17 Fuel level
103
Using the menu

appears.
selected.
Display
1 2
the display see chapter 2.1.

operation
e.g. language changeover: Function keys on the instrument panel with vehicle menu
Press key(4).
selected.
Press key (1 or 2) to select the desired language and
confirm with key (3)
Function keys on the multifunction steering wheel with vehicle menu
104
5.1.3 Adjusting the seat, steering wheel and 1

mirrors
2
Adjusting the seat
Comfort seats, Grammer
1 Adjust seat base angle 8
2 Adjust armrests
3 Adjust backrest angle 3
7
4 Adjust height of seat base
6 5 4
7 Adjust the reclined position
8 Adjust the front/back position) Controls for the Grammer seat with maximum equipment level

wheel.
First set the drivers seat, then adapt the steering wheel
to the modified seat position. 9
Press and hold the pushbutton(9) on the drivers seat
console with your heel.
Release pushbutton (9) again.
The steering wheel is locked.
Adjusting the mirrors Driver's seat console

10 Select side (left/right side)
11 Adjust mirror surface
12 Select mirror:
Curb mirror/main mirror/wide-angle mirror 11
13 Switch mirror heater on and off
The mirror heating check lamp (14) lights up when the
10
mirror heating is switched on.
14 Mirror heating check lamp 13
15 Briefly moving the main mirror outwards
The mirror swivels back automatically after about 14 12
30seconds.
15
Door module
105
1 2 3 4 5 6 7
5.1.4 Heating and ventilation
Functions on the control panel

1 Ventilate side windows
2 Dehumidification on/off
3 Air conditioner on/off
4 Heating temperature selection Controls for heating and ventilation
5 Fresh air/recirculating air
6 Blower
7 Outlet selection
5.1.5 Braking 9

8
The check lamp comes on.
Release the parking brake Parking brake in the gearshift "Parking brake" check lamp
console on the instrument panel
Pull the lever catch (9).
released position.
The check lamp goes out 10
11
Activate the engine brake .-
.%
%
Press key (10 or 11).

-
,
.%% 43.
,$,
Switch off the engine brake 6(7
Press key (10 or 11) again.
MAN BrakeMatic Sustained-action brake lever in Sustained-action brake lever in

vehicles without multifunctional vehicles with multifunction steering
BrakeMatic is switched on automatically after the ignition is
steering wheel wheel
switched on. No check lamp in rocker button (12) comes
on.
Switch off BrakeMatic

Press rocker button (12). 12
13
Switch on BrakeMatic BrakeMatic toggle switch
Press rocker button (12) again. Display showing BrakeMatic and
The check lamp in the rocker button goes out and cruise control switched on
symbol (13) appears on the display.
106

# -
MAN TipMatic DNR switch #,
1
Drive, forwards: D
1,
Neutral: N
Drive, reverse: R
Manoeuvre, reverse: RM
Note
Drive the vehicle in automatic mode if possible.
DNR switch
Switch between automatic and manual mode:
Press key(2).
In vehicles with multifunction steering wheel: Press
2 3 4
handle(4). .-
.%
%
Upshift:
One gear: Briefly pull steering column switch (1 or 3) ,$,
.%% 43.
, -
towards the steering wheel. 2$3

Downshift:
1
One gear: Briefly push steering column switch (1 or 3)
Several gears: Push and hold the steering column Steering column switch in vehicles Steering column switch in vehicles
switch.
wheel
Display: "Automatic", in "neutral" Display: "Manual", maximum

shift position number of gears which can be
engaged
107
6 8
frame is lowered! 4
If the vehicle has a lowered frame, it must only be
3 9
moved slowly and carefully.
10
1

remote control into the holder on the console
of the driver's seat.
ECAS remote control

1 Manual lifting
2 Manual lowering
3 Memory key 1
4 Memory key 2
suspension)
9 Ride height
10 Stop key

Press key (9).
Press keys (7) and (5) again to switch off ECAS remote
control.
The corresponding check lamps (8), (6) go out.
108
2
5.1.8 Starting and switching off the engine
3
Ignition lock
1
4 Start position
Starting the engine

necessary.
Unlock the steering wheel.
the heating-up procedure has started,
an audible signal sounds and
the "flame start" check lamp (5) goes out.
engine and release the ignition key.
Stopping the engine

If the engine has been running under considerable load, Only in vehicles with a flame start system: "Flame start" check lamp on the
display
do not stop it immediately but let it idle briefly first.
Stop the vehicle.

wing extension.
109
5.2.1 Tilting the cab
Safety instructions
Danger! Caution!
Danger of injury during the tilting process! Danger of refrigerator compartment damage!
The hydraulic cylinder is not suitable for holding Air bubbles which enter the cooling circuit due to
the cab in any position. tilting can impair the cooling system.
Only tilt the cab when the vehicle is in a Once the cab has been tilted backwards, do
horizontal position. not switch the refrigerator compartment back
In the interests of safety, keep the tilting area in on for at least 2 hours.
front of the cab clear.
No-one is allowed to be positioned wholly or in Caution!
part between the cab and chassis during the Danger of bodywork damage!
tilting process. The closed front flap is damaged when tilting the
Never lean on the vehicle whilst the cab is cab.
being tilted. Open the front flap before tilting the cab
Always tilt the cab forwards to its final position. forwards.
Warning!
The function of a pacemaker can be severely
impaired due to the EM radiation from the engine
control unit!
People who have a pacemaker fitted must
keep a distance of at least 20cm from the
running engine.
Before tilting forwards

Use wheel chocks to prevent the vehicle from rolling
away.
Move the selector lever to neutral.
Secure any loose objects in the cab.
Empty the storage box.
Switch off the auxiliary heater.
Empty, switch off and defrost the refrigerator
compartment.
Close the doors.
Release the lock in the cab, open the front flap.
110
2
Tilting the cab hydraulically
Danger! 2
The cab drops suddenly forwards over the last 10
to 15cm!
1
In the interests of safety, keep the tilting area in
front of the cab clear. 1
In the double cab, lower the safety support
onto the cab tilt ram.
The changeover valve for tilting the cab is fitted behind the
rear wall of the cab. Changeover valve cab C Changeover valve cab L, LX
Move the lever of the changeover valve to the right as
far as the stop (1).
Connect two pipe sections (vehicle tool kit) together, 4
insert in the socket (2) and pump.
The cab locks release the cab.
The cab tilts forwards.
4
Continue pumping until the cab has reached its end
position 3
Lowering the cab hydraulically
3
Danger!
The cab suddenly drops into the cab lock over the
last 10 to 15cm!
Changeover valve cab C Changeover valve cab L, LX
Danger!
If the cab is not locked, it can tilt forwards on
braking and cause serious accidents!
Always lower the cab as far as the limit position
and make sure it is engaged.
With a long cab: Open the cover in the entrance. After tilting
Move the lever of the changeover valve to the left as far Before the truck is driven, the lever of the changeover
as the stop (3). valve must always be moved to the left, as far as the
Connect two pipe sections (vehicle tool kit) together, stop.
insert in the socket (4) and pump, until the cab is The "cab lock" warning light in the panel of check lamps
lowered automatically and can be heard to engage in must go out.
the cab locks Also, the "STOP" symbol with the "LOCK CAB" mes-
Close the cover in the entrance sage must go out on the driver's display.
111
5.2.2 Checking service products
Checking the engine oil level

2
The vehicle must be standing on level ground in order
for the oil level to be checked.
The engine must be cold or have been stopped for the
minimum time specified in the table. 1
Engine oil level check 3
Oil temperature Waiting time

Maintenance points under the front flap
0C 90min
20C 45min
50C 5min
80C 4min
110C 3min
Engine oil level via the driver's display (optional)

(Operating data Engine data Oil level)
or
With the front flap open, check using the dipstick (1).
The position of the dipstick varies depending on the
engine variant.
Topping up engine oil

Top up the missing oil through the filler pipe (2).
Caution!
Too much oil is detrimental to the engine and the
environment!
Do not exceed the maximum oil level.
Checking coolant
The vehicle must be on a level surface for checking the
coolant level.
Check the coolant level in the expansion tank (3) with

the front flap open and the engine cold.
Switch off the engine
Fluid level between the min. and max. marks on the

expansion tank.
112
Topping up coolant
1
Warning!
The cooling system is under pressure and at high
temperature!
Do not open the screw cap (1) unless the
engine has cooled down.
Only open the screw cap by 2 3 turns in
order to allow the excess pressure to escape.
Only then open fully.
Caution! Topping up coolant

Excessive temperature differences can damage
the engine.
If there has been a large coolant loss 2
and consequently the engine is at a high
temperature, do not pour in cold coolant.
Wait for the engine to cool down.
Checking the steering hydraulic fluid level

The vehicle must be parked on level ground in order for
the steering hydraulic fluid level to be checked.
Shift the gearbox to neutral.
Move the steering wheel to the straight-ahead position.
Start the engine.
Open the front flap.
Tilt the cab. Expansion tank for steering hydraulic fluid
Disconnect the plug connection
Check the level on the dipstick.
Fluid level with the engine running:
Top mark on the dipstick.
through the filler hole (2).

Close the tank, reconnect the plug connection.
Lower the cab.
Dipstick
113
Checking the clutch hydraulic fluid level 2

The vehicle must be parked on level ground in order for
the clutch hydraulic fluid level to be checked.
1

Check the level in the expansion tank (1).
Fluid level between the min. and max. marks on the
expansion tank.
through the filler hole (2). Clutch actuation expansion tank
3
5.2.3 Bleeding the fuel system
Caution!
Danger of bodywork damage!
The closed front flap is damaged when tilting the
cab.
Open the front flap before tilting the cab
forwards.
Switch on the ignition.

Tilt the cab.
Unscrew the hand pump primer (3). Pump tappet
Pump the primer until the overflow valve is heard to
open.
Press the primer down and screw it on tightly.
Lower the cab.
Close the front flap.
114
5.2.4 Changing a wheel
Danger!
Inadequate support can allow the vehicle to move
downwards uncontrollably and cause severe
injuries!
away.
Only place the jack on level, firm ground which
can support the weight.
Only use the jack for short jobs.
Use stands for longer jobs.
Warning!
Other vehicles represent a sustained and
increased risk of accidents at the breakdown site!
Always wear a high visibility tabard when
changing a wheel.
Secure the vehicle in accordance with the
applicable statutory directives.
Warning!
On all vehicles with air suspension: The jack
may slip out of position due to regulation of the
electronically controlled air suspension.
Switch off the ignition.
Wait for the ECAS system to adjust.
Switch off the battery master switch (optional).
115
Jacking points
Front axle with leaf-spring suspension, non-driven Rear axle with leaf-spring suspension
Rear axle with air suspension
Tightening torques for wheel nuts

6-hole rim (M18x1.5): 39020Nm
8-hole rim: 47525Nm
116
5.2.5 Tow-starting
Tow-starting is always the last alternative because of the
risk involved and the strain imposed on the vehicle and
driver. Without doubt, always prefer jump starting,
see chapter 2.2
It is not possible to tow-start vehicles with:

Engine, gearbox, transfer case, axle and steering
damage
Automatic gearbox
MAN TipMatic gearbox
Inadequate brake pressure
Batteries not installed
Batteries only partially charged
Safety instructions
Warning! Caution!
If the spring-loaded brake cylinders have been If the vehicle is tow-started too quickly, the engine
released by an external compressed air supply or may be damaged when the clutch is engaged.
mechanically ( see chapter 5.3.2): Tow-starting speed < 30km/h
The reservoir brake pressure is not sufficient to Do not tow-start in reverse.
ensure correct braking!
Do not tow-start the vehicle under any Tow-starting
circumstances if the spring-loaded actuated Turn the key to the "ignition on" position.
brake has been released according to Disengage the clutch
chapter5.3.2.
3rd gear (5/6-speed gearbox)
Warning! or
There is no steering support if the engine is Engage a high gear (58) in a 9-speed gearbox.
stopped! Considerable effort is required at the
steering wheel. Tow-start the vehicle until an adequate speed has been
Only tow-start on a straight road. reached.
Slowly engage the clutch and press the accelerator until
Do not tow-start in reverse. the engine starts.
Only tow-start with a towing bar, do not use a
cable. To attach the towing bar see chapter If the engine does not start within 15 seconds:
5.3.3. Disengage the clutch
Shift the gearbox to neutral.
In 9-speed gearboxes: Stop.
Tow-start the vehicle in the high range. Repeat the tow-starting procedure one more time at
most.
117
5.3 Towing
5.3.1 Notes
Safety instructions Towing with a damaged engine

If the engine is damaged, the brake system is no longer
Warning! supplied with sufficient compressed air. The existing
Significant risk of accidents due to lack of braking brake pressure may dissipate due to leakages. This can
effort!The brake system of the towing vehicle cause the spring-loaded accumulators to apply the brakes
cannot provide sufficient braking effort for the uncontrollably during driving.
entire combination.
Before towing, check the braking effort of the To release the spring-loaded accumulators:
broken-down vehicle. Supply compressed air via the filler connection "IN",
see chapter 5.3.2.
If the brake system of the broken-down vehicle is
functional: To have the towed vehicle participate automatically in
If towing with the broken-down vehicle lifted, braking:
connect the pneumatic brake system of the Connect the pneumatic brake system of the towed
broken-down vehicle to the towing vehicle vehicle to the towing vehicle, see chapter 5.3.6.
(automatic joint braking see chapter 5.3.6).
When towing with a towing bar, leave the If the power steering fails, the effort required at the steering
engine of the towed vehicle running. The towed wheel is very great. Without power steering:
vehicle must have a driver to steer and brake Only tow over short distances with a highly reduced
the vehicle. speed or with the front lifted, see chapter 5.3.4.
Do not steer when stationary, otherwise the steering
If the brake system of the broken-down vehicle is system might be damaged.
not functioning:
Maximum towing speed: 10km/h In all-wheel drive vehicles:
Only tow the vehicle as far as the nearest Engage the on-road range of the transfer case.
suitable MAN Service workshop.
Towing vehicles with damaged axles
Caution! In the event of axle damage, make sure the damaged axle
Danger of gearbox damage! Adequate lubrication does not have any contact with the ground during towing.
of the gearbox is not guaranteed when towing. As
a result, the gearbox is not allowed to be driven by In case of front axle damage:
the wheels during towing. Tow with the front lifted, see chapter 5.3.4.
For versions 4x2:
Before towing with a towing bar or with the In case of rear axle damage:
front lifted, always disconnect the driveline, Tow with the rear lifted, see chapter 5.3.5.
see chapter 3.
If the damaged axle cannot be lifted during towing:
For versions 4x4: Remove the axle shafts on the axle in question or
Disengage all-wheel drive if possible. load onto another vehicle.
Disconnect the driveline before towing,
see chapter 3.
118
5.3 Towing
5.3.2 Releasing spring-loaded accumulators 9RUUDWVGUXFN

]XJHULQJ
Function of the spring-loaded brake cylinders

The spring-loaded brake cylinder brake automatically if the 1
reservoir pressure in the spring-loaded accumulator circuit
has dropped below the release pressure (approx. 6.0bar).
2 3 4
Indications on the instrument panel:

The driver's display shows the "STOP" signal (1) with
the message "AIR PRESSURE TOO LOW".
The "brake system" (2) and "parking brake" (3) check
lamps come on. Displays on the instrument panel when spring-loaded brake
cylinders are activated (example: TGL/TGM from 2008)
The red central warning light (4) flashes.
An acoustic warning signal sounds.
Note
In case of a breakdown, the spring-loaded brake
cylinders can be released pneumatically or
mechanically.
Safety instructions When towing with a towing bar, leave the

engine of the towed vehicle running and have
Warning! the towed vehicle participate in braking.
Danger of a serious traffic accident due to lack of When towing with the broken-down vehicle
braking effort or malfunctions of the brake system! lifted, have the pneumatic brake system
After emergency release of the spring-loaded of the towed vehicle participate in braking
brake cylinders, the reservoir pressure in brake automatically. Pull out the ignition key and do
circuits 1 and 2 may not be sufficient to guarantee not press the brake pedal, in order to prevent
correct braking of the rear axle. Under certain malfunctions of the ABS and ASR.
circumstances, there may be no brake pressure See further instructions in the following
at all. A slow pressure loss in the spring-loaded chapters:
accumulator brake circuit can result in the spring- 5.3.3 (towing bar) or
loaded accumulators braking uncontrollably during 5.3.4 (front lifted) or
towing. 5.3.5 (rear lifted) as well as chapter
To ensure that the brake system on the towed 5.3.6 (connecting pneumatic brake systems).
vehicle is functioning:
Provide for a reservoir pressure in the spring- Warning!
loaded accumulator brake circuit by external Danger of injury if the vehicle is not secured!
supply from the towing vehicle, see next Secure the vehicle to prevent it from rolling
page. away before releasing the spring brake
cylinder.
119
5.3 Towing
1
Releasing spring-loaded accumulators pneumatically
During pneumatic release, compressed air is supplied from
another vehicle to the pneumatic brake system.
Necessary supply pressure:

Supply compressed air and release the spring-loaded

accumulators:
Switch on the ignition. Filler connection behind the front flap
Open the lock in the cab, open the front flap.
Remove the sealing cap from the filler connection (1).
Connect the inflating hose from the other vehicle to the
filler connection. 9RUUDWVGUXFN
]XJHULQJ
If brake circuit 3 contains sufficient reservoir pressure

2
(approx. 5.4 to 5.8bar):
The "STOP" symbol (2), the "brake system" (3) and
"parking brake" (4) check lamps as well as the central 3 4 5
warning light (5) go out.
The parking brake is now released.
Note
If the vehicle is towed with the front lifted: Displays on the instrument panel when spring-loaded brake cylinders are
activated (example: TGL/TGM from 2008)
Continue the compressed air supply during
towing as well.
120
5.3 Towing
Releasing spring-loaded accumulators using the

mechanical method
Warning!
Danger of accidents due to failure of the parking
brake!
The parking brake does not function after having
been mechanically released, even if the compressed
air system is charged. In the case of the mechanical
spring actuator emergency release device, there is
no indication that the emergency release device has
been released mechanically. The indication remains Spring-loaded accumulator variant Spring-loaded accumulator variant
NG3: Feature of the clamping band NG5: Feature of the flanging
on the driver's display, the "parking brake" check
lamp and the red central warning light in the panel of
check lamps and warning lights continue to be lit.
Only release the spring-loaded accumulators
mechanically if pneumatic release is not
possible.
Warning!
1
Danger of injury due to trapping!
It is essential to comply with the maximum
release torque of the installed spring-loaded
accumulator variant (NG3 or NG5)!
Caution!
Never use impact drivers to unscrew, screw
in or tighten the release spindle. Comply with
the maximum tightening torque of the installed Unscrewed release spindle on the spring-loaded brake cylinder NG3
spring-loaded accumulator variant (NG3 or NG5)!
Release the spring-loaded accumulator in version NG3:

2
Unscrew the release spindle (1) fully, approx. 60mm
(approx. 35mm on a leading or trailing axle), until the
braking effect is cancelled
Release torque of the release spindle: max. 35 Nm
The parking brake is now released and does not function.
panel remain lit.
Indicator (2) projects from the spring-loaded accumulator Inoperative spring-loaded brake cylinder NG3 with indicator sticking out (in
housing.
121
5.3 Towing

reached.
tighten it.
Tightening torque of the release spindle: 30 to 70Nm
The indicator is withdrawn again.
Have the brake system checked in a MAN Service Operational spring-loaded brake cylinder NG3 with retracted indicator (in
workshop.
Release the spring-loaded accumulator in version NG5:

Unscrew the release spindle (1) until the braking effect 1
is cancelled (max. 38 mm).
Release torque of the release spindle: max. 45Nm
The parking brake is now released and does not
function.
panel remain lit.
PD[
In three and four-axle vehicles with air suspension: PP
Indicator projects from the spring-loaded accumulator
housing.
Inoperative spring-loaded brake cylinder NG5 with unscrewed release
spindle
reached.
tighten it.
Tightening torque of the release spindle: 30 to 70Nm
In three and four-axle vehicles with air suspension. The
indicator is pulled back again.
Have the brake system checked in a MAN Service
workshop.
Operational spring-loaded brake cylinder NG5 with tightened release

spindle
122
5.3 Towing
5.3.3 Towing with a towing bar
Warning! Caution!
Danger of accidents! Overloading or misusing the tow bar hitch can lead
Leave the engine of the towed vehicle running. to damage to the vehicle frame!
The towed vehicle must have a driver to steer Only use the tow bar hitch for pulling, never for
and brake the vehicle. lifting the vehicle.
Exclusively use a towing bar for towing, only Do not exceed the permitted pulling force at
use cables for recovery, see chapter 5.4. the tow bar hitch:
Refer to the table in appendix6.3 to find the
Warning! maximum permitted pulling forces on the front
Danger of accidents due to uncontrolled driving cross member when towing straight-ahead
behaviour of the towing vehicle if the towed vehicle and at an angle.
is not also steered appropriately!
Only tow a vehicle with a towing bar if its Caution!
steering system is functioning. In vehicles with air suspension (ECAS):
If the steering system is damaged, lift the The air suspension system can be damaged
vehicle at the front, see chapter 5.3.4. if the suspension fails due to lack of reservoir
pressure in the brake system.
In case of engine damage, the power steering fails Make sure there is adequate reservoir pressure
and the necessary steering forces become very in the brake system by external supply from the
high. In case of power steering failure: towing vehicle, see chapter 5.3.2 "Releasing
Only tow at highly reduced speed or with the spring-loaded accumulators pneumatically".
front lifted, see chapter 5.3.4.
If the air suspension system cannot be activated
Caution! even by an external compressed air supply:
Towing the vehicle when loading can cause Only tow the vehicle slowly and with increased
additional damage! caution.
Unload the towed vehicle before attaching the
towing bar.
If unloading is not possible, tow with increased
caution.
123
5.3 Towing
Attaching a towing bar

Precondition: The driveline is disconnected,
see chapter 3.
Open the number plate carrier. 2 1

Pull the cotter pin (1) out of the pin (2).
Pull the pin out of the tow bar hitch.
Insert the towing bar and secure it with the pin.
Secure the pin with the cotter pin.
Towing
Switch on the battery master switch. Tow bar hitch behind the number plate carrier
steering lock.
possible. 2
Shift the gearbox to neutral. 3
Do not exceed the maximum pulling force.
1
Ignition key positions
124
5.3 Towing
5.3.4 Towing with the front of the vehicle lifted
Warning!
An incorrectly lifted vehicle can cause a severe
traffic accident during towing! In any event,
damage to the vehicle will be unavoidable.
Only lift the front axle using suitable
equipment, and make sure it is evenly lifted.
Never lift the vehicle using the tow bar hitch.
In case of vehicles which have been involved in
an accident, check the connections between
the frame components as well as between the
frame and front axle.
Warning!
Danger of accidents due to inadequate braking
effort!
Connect the rear axle and trailer brake circuit
of the towed vehicle to the towing vehicle.
Ensure reservoir pressure by external supply;
see chapter 5.3.6.
Warning!
and ASR! Towing with the vehicle lifted and the
electronic brake system activated also creates
numerous fault entries in the diagnostic system.
With the vehicle lifted at the front:
Turn the ignition key to position "0" and remove
it.
Do not press the brake pedal. Pressing the
brake pedal activates the electronic brake
system, even if the ignition is switched off.
Caution!
Lifting and towing a laden vehicle can cause
additional damage!
Unload the towed vehicle if possible before
lifting.
125
5.3 Towing
Raising the vehicle with the wheels
Warning!
and ASR!
Note
Lifting the vehicle at the front wheels is described
here with the example of a wheel lift unit. Correct Fastening the wheels to the wheel grippers using straps
use of wheel grippers is also possible and
permitted.
Preconditions:
Hooking in the wheel lift unit and lifting the vehicle:

Move the wheel lift unit under the vehicle and set it to
Lift the vehicle.
Secure both wheels to the wheel lift unit using straps.
Additionally secure the cross head to the front axle with
chains.
Ensure adequate suspension travel:

Make sure that the rear end does not touch the ground Inadequate ground clearance at rear; underbody guard would collide with
unevennesses in the ground
possible, raise the vehicle slightly with air suspension.
If this is not possible:
lower the underbody lift to a flat angle. When doing
this, make sure that the front of the vehicle remains far
enough away from the cross head.
Also make sure there is adequate distance between the front axle and
cross head at the front
126
5.3 Towing
Lifting the vehicle with axle forks
Warning!
and ASR!
Preconditions: 1
Pull or place the vehicle onto ramps or blocks (1).
In order to get axle forks under the front axle, it is necessary for the vehicle
to be on blocks or ramps
Vehicles with air suspension:
Move the underbody lift under the vehicle and hook the
axle forks onto the front axle.
that the steering linkage, springs, anti-roll bars, hoses
and cables are not damaged.
Secure the front axle onto the underbody lift with
chains.
Hooking axle forks onto the air-sprung front axle and securing with chains
127
5.3 Towing
Vehicles with leaf suspension:

2
Either grip the axle beam with axle forks or
use suitable holding devices (3) to grip the spring
shackles of the leaf springs (1) or (2).
that the steering linkage, anti-roll bars, hoses and 1
cables are not damaged.
Secure the frame onto the underbody lift using chains.

Make sure that the rear end does not touch the ground Force application points when lifting at the spring shackles

possible, raise the vehicle slightly with air suspension.
If this is not possible: Lower the underbody lift at a flat
angle. When doing this, make sure that the front of the
vehicle remains far enough away from the cross head.
Holding spring shackles with holding devices
Inadequate ground clearance at rear; underbody guard would collide with

unevennesses in the ground
128
5.3 Towing
5.3.5 Towing with the rear of the vehicle raised
Warning! Warning!
An incorrectly lifted vehicle can cause a severe Dangers of accidents due to inadequate braking
traffic accident during towing! In any event, effort!
damage to the vehicle will be unavoidable. Connect the front axle brake circuit of the
Only lift the front axle using suitable towed vehicle to the towing vehicle. Ensure
equipment, and make sure it is evenly lifted. reservoir pressure by external supply;
On vehicles that have been involved in an see chapter 5.3.6.
accident, check the connections between the
frame components and between the frame and Caution!
axles. Lifting and towing a laden vehicle can cause
In vehicles with two rear axles: additional damage!
Lift the vehicle until the wheels of both rear Unload the towed vehicle before lifting.
axles are no longer in contact with the ground.
The rear axle wheels must maintain adequate Note
ground clearance during towing, even when There is no need to disconnect the driveline when
the ground is uneven. towing with the rear lifted, if the front axle is not
driven.
Warning!
The unsecured front axle can cause a severe
traffic accident due to uncontrolled steering!
Set the front wheels to the straight-ahead
position and let the steering lock engage.
It is essential to secure the steering wheel with
straps as well. The steering lock alone cannot
withstand the forces.
Warning!
Dangers of accidents due to malfunctions of ABS
and ASR!
Do not press the brake pedal. Pressing the
brake pedal activates the electronic brake Securing the steering wheel
system, even if the ignition is switched off.
129
5.3 Towing
Raising the vehicle with the wheels
Warning!
and ASR!
Note
Lifting the vehicle at the rear wheels is described
here taking example of wheel grippers. Correct Towing with the rear wheels lifted
use of a wheel lift unit is also possible and
permitted.
Preliminary work:
Hooking in the wheel grippers:

Lifting the vehicle
1
Vehicles with air suspension: Make sure there is
sufficient distance between the air bellows carrier (1)
and cross head(2). 2
Lift vehicles with two rear axles until all rear wheels are Make sure there is sufficient distance between the air bellows carrier and
cross head of the underbody lift
no longer in contact with the ground.

Make sure that the underbody guard at the front does
not make contact with the ground whilst driving, even
when the ground is uneven. If possible, raise the vehicle
slightly with air suspension.
Fastening the wheels to the wheel grippers using straps
130
5.3 Towing
Lifting the vehicle at the axles
Warning!
and ASR!
If the vehicle cannot be lifted at the wheels, e.g. after an

accident involving axle damage: L ift the vehicle at the axles.
Towing with the rear axle lifted
Preliminary work:
Pull the vehicle onto ramps (1).
In addition in vehicles with two rear axles and air

suspension:
Tie up the front axle.
Vehicles with air suspension:

Drive the underbody lift under the vehicle
Hook axle forks onto the rear axle beam. 1
that springs, hoses and cables are not damaged.
Secure the rear axle beam to the underbody lift with In order to get axle forks under the axle, it is necessary for the vehicle to be
on ramps
chains.
Hooking axle forks onto the air-sprung rear axle and securing with chains
131
5.3 Towing
Vehicles with leaf suspension:

Either use axle forks to grip the axle beam
or
grip using suitable holding devices (2) at the spring
shackles of the leaf springs (1). (Suitable holding
devices can be obtained from Wolfgang Brechtel
GmbH, for example, see also appendix 6.1.)
Vehicles with two rear axles:

Lift the vehicle until all rear wheels are no longer in 2
contact with the ground.

Force application when lifting at the spring shackles
Holding devices for spring shackles
132
5.3 Towing
5.3.6 Connecting pneumatic brake systems
Notes Warning!
For automatic joint braking, connect the pneumatic brake Danger of injury by compressed air! The pedal
systems of the two vehicles together. brake valve is under high pressure when the brake
pedal in the cab is pressed.
If the vehicle is lifted at the front: Never press the brake pedal whilst working in
Connect the rear axle and trailer brake circuit of the the area of the pedal brake valve.
towed vehicle to the towing vehicle.
Ensure reservoir pressure by external supply from the
towing vehicle. Safety information if the vehicle is towed with the rear lifted:
If the vehicle is lifted at the rear: Warning!

Connect the front axle brake circuit of the towed vehicle Danger of accident if the brake force in the towed
to the towing vehicle. vehicle is too high or too low! Depending on the
The front axle is automatically braked as well load condition and the condition of the road, the
irrespective of the reservoir pressure in the front axle braking effort transferred from the towing vehicle
brake circuit (circuit 1). may be too high or too low. The anti-lock brake
system of the towed vehicle does not function.
If compressed air has been supplied to release the spring- Supply brake pressure to the towed vehicle
loaded brake cylinder: using a pressure control device.
Continue to ensure the reservoir pressure in the spring- At the start of the towing procedure, observe
loaded brake circuit by external supply from the towing the braking behaviour of the towed vehicle
vehicle. carefully.
Set the brake force on the towed vehicle as
required using the pressure control device.
133
5.3 Towing
Joint braking with the rear wheels 1

(for towing with the front lifted):
2
Open connection 23 (2) on the central brake unit with a
19 mm spanner (parts no. 08.06003.9000,
Connect line 23 to the yellow trailer brake connection of
the towing vehicle.
Remove the sealing cap from the filler connection (1).

Connect the inflating hose from the other vehicle to the Central brake unit behind the front flap
filler connection.
Necessary supply pressure: 7.5 to 12.5bar
Joint braking with the front wheels

(for towing with the rear lifted):

Open connections 2.1 (3) and 2.2 (4) on the central
brake unit using a 19 mm spanner (parts no.
08.06003.9000, see also appendix 6.1).
Connect 2.1 and 2.2 to the yellow trailer brake 4 3
connection of the towing vehicle, via a pressure control
device in each case.
Central brake unit behind the front flap
Set the brake force on the towed vehicle as required
using the pressure control devices
After towing
Warning!
Significant risk of accidents if the brake system is
faulty!
Immediately after disconnecting the pneumatic
brake system: Connect the line correctly back
to the pedal brake valve.
Before taking the vehicle back into operation:
Have the entire brake system examined in a
MAN Service workshop.
134
5.4 Recovery
5.4.1 Notes
In order to recover a broken-down vehicle as safely and with
as little damage as possible, comply with the following rules:
Stabilising the vehicle

If possible, use lifting cushions to right and stabilise a
tipped-over vehicle (e.g. on an embankment) before
lifting it.
Lifting cushions can slip during righting, and jump out at

high speed.
Secure lifting cushions to prevent them jumping out.
If possible, vacate the vicinity of the inflated lifting
cushion.
Distributing forces evenly

Applying force via a few points leads to stresses and
overloading.
applying force.
Danger of frame distortion or cracking.

Avoid applying force at one side only.
Avoid point loads and peak stresses:

Use straps which are as wide as possible.
Only use the trailer tow hitch for manoeuvring on a
consolidated road. Secure pulling straps to the rear
cross member in order to pull the vehicle backwards.
Use load equalisation rollers in order to encourage even
pulling.
135
5.4 Recovery
Reducing loadings
Ideally, the vehicle should be unloaded before recovery.
Only recover a laden vehicle:
In an emergency or

)
)
if unloading is not technically feasible or
) ) )!)
inadvisable (e.g. refrigerated vehicle) ) )
When recovering a laden vehicle, ensure that the force

is distributed over a particularly wide area.

Obtuse angles increase the pulling force in the Correct: Wrong:
When pulling straight ahead, the The angled pull means that too
straps and the strain on the force application points
pulling force is no greater than much pulling force has to be
significantly. absolutely necessary. applied.
The pulling straps should form a triangle with the most
acute angle possible, and with sides of even length.

Avoid pulling at an angle.
The tensile force required increases significantly if
pulling away from the lengthways direction of the
vehicle.
136
5.4 Recovery
Avoiding other damage

Do not damage frame add-ons, lines, cables or hoses
on the vehicle.
Select suitable components on the vehicle if possible
for applying force, see chapter 5.4.2.
Avoid force application via safety components.

The affected safety components must be checked by a
MAN Service workshop. List of safety components
see appendix 6.2.
Duties of care of the operating personnel

The variety and unpredictability of possible recovery
situations means it is impossible to consider all
eventualities here. Qualified and experienced recovery
personnel are required for safe and successful recovery
operations. The recovery personnel are responsible for
deciding on the spot regarding what measures and tools
are suitable. The instructions and information in this guide
are only intended as additional information.
137
5.4 Recovery
5.4.2 Suitable force application points
During recovery, always apply the forces to the vehicle These components do not have unlimited load capacity.
via the following points: Applying force via a few points leads to overloading, in
Frame front carrier (bumper must be removed) particular when lifting the tractor/trailer combination.
Spring articulation points Use as many points as possible, distributed evenly, for
Rear crossmember applying force.
Wheel hubs Always avoid applying force or transmitting force via safety
Limited suitability: Longitudinal link block, directly on components. Refer to the appendix for a list of safety
the frame components.
138
5.4 Recovery
The safety components also include all axle components. Also unsuitable for force application:
The axle beams can withstand pulling forces, depending Underride guard
on the axle design. See the next chapter about this. Built-on parts
Axle guidance components
Tubular crossmember
139
5.4 Recovery
5.4.3 Removing the front bumper
Caution!
Do not exceed the permitted pulling force at
the front cross member:
The maximum pulling forces on the front
cross member during pulling straight ahead
and at an angle can be seen in the table in 1
appendix6.3.
Note Force application via frame front member
The front tow bar hitch is a manoeuvring device

and only suitable for recovery to a limited extent.
The frame front member (1) is suitable for pulling
the vehicle forwards.
Remove the front bumper in order to access the
frame front member.
4
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.
Remove cover caps from the bumper, remove nuts (4).
2 3
Disconnect the electrical connections (5).
If fitted: Disconnect the supply pipe to the headlight
washing system and tie it up (6).
Watch out for lines, cables and hoses. Removing the front bumper
Disconnecting electrical connections and hoses
140
5.4 Recovery
5.4.4 Pulling the vehicle forwards 2 1

Remove the front bumper, see chapter 5.4.3.
Loop cables or straps around the frame front member
(1). When doing this, do not crush the electric cables
(2) on the frame front member, and watch out for the
hydraulic lines (3). 3
Use tensioning straps to secure both pulling straps to

the lengthways members, to prevent them from slipping
towards the middle.
Attach the pulling straps at as acute an angle as
possible to the towing vehicle. Make sure both pulling When fitting the towing equipment, watch out for electric cables and
hydraulic lines
straps have the same length, in order to avoid pulling at
an angle.
than15.
is stuck.
5.4.5 Pulling the vehicle backwards

Disconnect lines, compressed air vessels, etc. as far
as necessary and secure them to prevent them falling
down.
Loop cables or straps around the rear crossmember (4). 4
Do not crush electrical cables when doing this. Insert
a block of wood between the pulling straps and rear Pulling at the rear crossmember
cross member.
Attach the pulling straps at as acute an angle as

possible to the towing vehicle. Make sure both pulling
straps have the same length, in order to avoid pulling at
an angle.
than15.
is stuck.
141
5.4 Recovery
5.4.6 Righting the vehicle

Righting:
Distribute the force application points as widely as
possible.
Apply forces from as many directions as possible in
order to stabilise the vehicle.
If possible: Use lifting cushions for righting; additionally
pull with wire cables.
Apply a counterforce by pulling vertically on the wheel
hubs during righting, in order to prevent the vehicle from
suddenly tipping back. Use a suitable force application Wheel hub clamp on the front axle
system for wheel hubs for this purpose, reference
address see appendix. It is essential to comply with
the installation instructions for the attachment fittings.
After righting:
Caution!
Danger of engine damage oil knock!
Do not attempt to start the vehicle engine.
5.4.7 Lifting the vehicle

Points for lifting with lifting cushions:
Crossmember
Axle beam (in vehicles with leaf suspension)
Points for lifting with an underbody lift:

Crossmember
Wheel hubs
Spring articulation points (in vehicles with leaf
suspension)
Front towing eyes
(in vehicles with a plastic bumper)
Points for lifting with a jack:

See chapter 5.2.4.
142
5.4 Recovery
5.4.8 Lifting the vehicle high

Lift the vehicle with a mobile crane.
Use suitable attachment fittings for applying force, e.g.
wheel hub clamps (reference address
see appendix 6.1). It is essential to comply with the
installation instructions for the wheel hub clamps.
Attach the wheel hub clamps to all wheels if possible.
If necessary, clamp blocks of wood between the pulling
straps and tyres in order to avoid damaging the wings.
Pulling straps should form as acute a triangle as
possible, with sides of even length.
143
Notes
144
6 Appendix
6.1 Tools and materials
6.1.1 Disconnecting the driveline
Reference sources
Designation Purpose MAN parts no. Others
Removing the transverse differential lock
Octagonal socket 80.99603.0261
switch
Pressure spindle M18x1.5 Blocking the differential box 80.99613.0027
Filling oil after removing

Oil filler tank 80.99629.0011
planetary final drive shaft
Removing the locking ring from the planetary
Internal circlip pliers 08.04046.9000
final drive shaft
Removing the planetary final drive shaft with
Bolt M8x120 and nut M8
sun gear and axial bearing
Removing and installing axle shafts in
Support handle 80.99617.0005
conjunction with stud bolt
Removing and installing axle shafts in
Stud bolt 06.06138.0712
conjunction with support handle
Do-it-yourself.
E.g. remove the wheel
Dummy cover Sealing the wheel hub opening on a hypoid
covers from an axle
for 17.5, 19.5 and 22.5 tyres axle
shaft that has been
taken out of service.
6.1.2 Connecting brake compressed air systems
Reference sources
Releasing spring-loaded accumulators in
Pneumatic filler lines an emergency, supplying reservoir brake Prolux-System-technik
pressure
Pressure control devices with pressure Adapting the brake pressure on the towed E.g. Prolux-System-

gauge vehicle technik
145
6 Appendix
6.1 Tools and and equipment
6.1.3 TGX, TGS and TGA series
Reference sources
Pulling or towing the vehicle with a plastic
Towing lug 81.42015.6025
bumper
Shunting coupling 81.42015.6028
bumper
Thread cleaner Removing dirt from the holding thread 08.42914.0509
Centering sleeve for steel rim Removing and fitting wheels 80.99619-0067
Centering sleeve for alloy rim Removing and fitting wheels 81.9302121-0089
E.g. Brechtel GmbH; Prolux

Lockable holding forks Systemtechnik GmbH &
bumper
Co. KG
E.g. Bechtel GmbH; Prolux
Holding devices for leaf springs Towing vehicles with leaf springs lifted Systemtechnik GmbH &
Co. KG
Wheel hub clamps E.g. Krause GmbH;
for 17.5, 19.5 and 22.5 tyres Bsmann GmbH
6.1.4 Series TGL/TGM
Reference sources
E.g. Brechtel GmbH; Prolux
Holding devices for leaf springs Towing vehicles with leaf springs lifted Systemtechnik GmbH &
Co. KG
Unscrewing connection screw fittings at the
19 mm spanner 08.06003.9000
central brake unit
Wheel hub clamps E.g. Krause GmbH;
for 17.5, 19.5 and 22.5 tyres Bsmann GmbH
6.1.5 Reference addresses for other manufacturers
Wolfgang Brechtel GmbH 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 Operational safety of the vehicle
Warning!
Damage to safety components can lead to traffic
accidents with serious consequences!
When recovering and towing, always avoid
applying force to safety components.
Have the affected safety components checked
by an authorised MAN Service workshop. L ist
of safety components see appendix.
Vehicles that have been recovered or towed

must always be checked by an authorised
MAN Service workshop to make sure they are
in correct technical condition and have not
been damaged.
6.2.2 Safety components in the commercial

vehicle
Steering system (power-transmitting components Wheel

between the steering wheel and the road wheels) Wheel bearing attachment, wheel hub
Steering wheel, steering shaft, steering column, joints, Wheel, wheel attachment and tyres
steering gear, pitman arm
Eccentric arm, drop arm, drag links, track rods and their Brake, braking device on wheel
assemblies Actuating device, power transmission device
Fastenings for attaching steering gear to frame (steering (mechanical)
block) Pneumatic operation
Steering lock Brake drum, brake disc, incl. wheel brake cylinder
fastenings
Steering axle Brake lining including brake shoes
Steering knuckle, kingpin, axle beam Brake lining/brake pad fastenings
Braking power support
Rear axle
Rear axle tube, axle beam Propshaft
Axle guidance, incl. fastenings Cab

Spring guidance leaf, spring block, spring pin, spring Cab mounting
attachment, spring bracket Safety belt with fastenings
Leading links, trailing links, transfer links and fastenings Glass
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)
Tow bar hitch 330k N (33t) 200k N (20t)
Two towing eyes with shunting coupling 400k N (40t) 200k N (20t)
6.3.2 Series TGX, TGS


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)
Two towing eyes with shunting coupling:
4x2/6x2, leaf suspension on FA 280k N (28t) 180k N (18t)
Shackle (each) 100k N (10t) 100k N (10t)
6.3.3 Series TGL, TGM


Attachment point
Coupling jaw:
Tonnages 7.5t to 10t 50k N (5t) 30k N (3t)
Tonnages 12t to 26t 130k N (13t) 80k N (8t)
Front crossmember (only recovery see page 140):
Tonnages 7.5t to 10t 75k N (7.5t) 50k N (5t)
Tonnages 12t to 26t 190k N (19t) 120k N (12t)
Shackle (each) 50k N (5t) 50k N (5t)
148
6 Appendix
6.4 Index
A Display . . . . . . . . . . . . . . . . . . . . . . . . . . 11, 32, 41, 43, 104

About this handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 62, 119
AdBlue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2529, 145
Adjusting the mirrors . . . . . . . . . . . . . . . . . . . . . 34, 45, 105
Adjusting the seat . . . . . . . . . . . . . . . . . . . . . . . 33, 44, 105
Adjusting the steering wheel . . . . . . . . . . . . . . . 33, 44, 105 E
Air suspension . . . . . . . . . . . . . . . . 38, 49, 75, 83, 108, 127 ECAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
All-wheel drive . . . . . . . 8, 26, 6061, 8184, 118, 130131 ECAS . . . . . . . . . . . . . . . . . . . 38, 49, 56, 66, 108, 115, 123
Attaching the towing equipment . . . . . . . . . . . . . . . . 67, 69 Engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 106
Automatic joint braking . . . . . . . . . . . . . . . . . . . . . . 85, 133 Engine damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61, 118
Axle damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61, 118
Axle forks . . . . . . . . . . . . . 71, 7578, 84, 127128, 131132
Axle guidance components . . . . . . . . . . . . . . . . . . .91, 139 F
Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Filling connections . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 87
B Force application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Battery master switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Force application points . . . . . . . . . . . . 9192, 9498, 138
Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . 56, 114 Force distribution . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 136
BrakeMatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 47, 106 Four-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . 7577,
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 46, 106 Four-axle vehicles, laden . . . . . . . . . . . . . . . . . . . . . . . . . 78
Braking effort . . . . . . . . . . . . . . . . . 35, 46, 60, 62, 118119 Four-point link (X-link) . . . . . . . . . . . . . . . . . . . . . . . 98, 147
Braking system . . . . . . . . . . . . . . . . . . . . . 62, 118119, 133 Frame front member . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Brands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front axle with air suspension . . . . . . . . . . . . . . . . . . . . . 95
Front axle with leaf suspension . . . . . . . . . . . . . . . . . . . . 94
C
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51, 110, 147 G
Changing a wheel . . . . . . . . . . . . . . . . . . . . 5658, 115116 Gearbox operation . . . . . . . . . . . . . . . . . . . . . . 36, 47, 107
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Checking the engine oil . . . . . . . . . . . . . . . . . . . . . . 54, 112
Check lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 H
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 114 Heating and ventilation . . . . . . . . . . . . . . . . . . . 34, 45, 106
Clutch hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 114 Hydraulic fluid level . . . . . . . . . . . . . . . . . . . . . . . . . 55, 113
ComfortShift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 48 Hydraulic fluid level of the clutch . . . . . . . . . . . . . . . 55, 114
Compressed air . . . . . . . . . . . . . . . . . . . . 8586, 120, 133 Hydraulicfront axle drive . . . . . . . . . . . . . . . . . . . . . . . . . 26
Connecting brake systems . . . . . . . . . . . . . . . . . . . . 8586 HydroDrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7, 26, 61
Connecting pneumatic brake systems . . . . . . . . 8586, 133 Hypoid axle shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 27, 28
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54, 112113
Cross head . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 126, 130
I
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D Instrument panel . . . . . . . . . . . . . . . . . . . . . 31, 40, 42, 103
Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Differential box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27, 145
149
6 Appendix
6.4 Index
J Pulling the vehicle backwards . . . . . . . . . . . . . . . . 101, 141

Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5657, 116 Pulling the vehicle forwards . . . . . . . . . . . . . . . . . . 100, 141
Joint braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Pump tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
K R
Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ramps . . . . . . . . . . . . . . . . . . . . . . 74, 7677, 84, 127, 131
Range of vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear axle with leaf suspension . . . . . . . . . . . . . . . . . . . . 96
L Rear crossmember . . . . . . . . . . . . 81, 9192, 101, 138, 141
Language changeover . . . . . . . . . . . . . . . . 32, 41, 43, 104 Recovery . . . . . . . . . . . . . . . . . . . . . . . . . 88102, 135143
Leaf-sprung vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Release spindle . . . . . . . . . . . . . . . . . . . . . . . . 6465, 121
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Release torque . . . . . . . . . . . . . . . . . . . . . . . . . 6465, 121
Lifting . . . . . 70, 7278, 8184, 102, 126127, 130131, 142 Releasing the spring actuator . . . . . . . . . . . 6265, 119122
Lifting cushions . . . . . . . . . . . . . . . . . . . . 88, 101, 135, 142 Removing the front bumper (TGL/TGM) . . . . . . . . . . . . 140
Lifting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 102, 142 Removing the propshaft . . . . . . . . . . . . . . . . . . . . . . . . . 26
Longitudinal link block . . . . . . . . . . . . . . . . . . . . . . 91, 138 Retarder/Intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 46
Righting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 142
Righting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . 101, 142
M Risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MAN parts no. . . . . . . . . . . . . . . . . . . . . . . . . . . . 145146
Manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 48
Mobile crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102, 143 S
Model code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Model plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Mode switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 47, 107 Securing the steering wheel . . . . . . . . . . . . . . . . . . 79, 129
Multifunction steering wheel . . . . . . 32, 36, 43, 47, 104, 107 ServoShift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37, 48
Setting the ride height . . . . . . . . . . . . . . . . . . . . 38, 49, 108
Shunting coupling . . . . . . . . . . . . . . . . . . . . . . . 67, 92, 100
O Spring articulation points . . . . . . . . . . . . . 91, 102, 138, 142
Oil knock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 142 Spring-loaded accumulator variant . . . . . . . 6465, 121122
Operating equipment . . . . . . . . . . . . . . . . . . . . . . . 54, 112 Starting the engine . . . . . . . . . . . . . . . . . . . . . . 39, 50, 109
Operators manual . . . . . . . . . . . . . . . . . . . . . . 31, 40, 103 Steel bumper . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 93, 100
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 113
Supplying brake reservoir pressure from an
P external source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 46, 106 Supplying compressed air . . . . . . . . . . . . . . . . 63, 87, 120
Planetary final drive shaft . . . . . . . . . . . . . . . . . 27, 29, 145 Supply pressure . . . . . . . . . . . . . . . . . . . . . 63, 87, 120, 134
Plastic bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 100 Switching off the engine . . . . . . . . . . . . . . . . . . 39, 50, 109
Pneumatic brake system . . . . . . . . . . . . . . . . . . . . . . . . . 85
Pulling at an angle . . . . . . . . . . . . . . . . . . . . . . . . . . 90, 136
Pulling force . . . . . . . . . . . . . 67, 69, 89, 100, 123, 140, 148 T
Pulling force application . . . . . . . . . . . . . . . . . . . . . . . . 100 Technical status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pulling straight ahead . . . . . . . . . . . . . . . . . . . . . . . 90, 136 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 ever-
growing 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
Agency performing the work: Thewald Kommunikation

2011 MAN Truck & Bus AG
D 81.99185-1052 mu 12/11 Printed in Germany
The information in text and illustrations is non-binding.
Subject to modifications in response to technical progress. T rucknology mobile.
anual of Breakdown Assistance I Recovery I
M
MANTruck&BusAG
Towing.
Postfach 50 06 20
D-80976 Mnchen
www.mantruckandbus.com
A MAN Group company

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D 81.

99185-1052 mu 12/11 Printed in Germany

We are delighted to present you our handbook

After Sales Documentation

Central Testing Department

Agency performing the work: Thewald Kommunikation

Wishing you every success,

Self-image (VIP class buses)

As an international supplier of trucks, buses, coaches, engines and components,

Product description (Trucks, bus chassis)

One of the leading suppliers of trucks, buses, coaches and corresponding

Service contracts with differentiated levels of service for maintenance

TeleMatics, ProfiDrive (driving training), communication on board, fleet

Financing, leasing, full service (CombiContract), insurance

Vehicles in all categories, semitrailers, trailers for all transport functions

Used vehicles (trucks, buses, coaches) of all brands and categories

MAN sales regions and production sites

Poland South Africa

Turkey Mexico India (MAN FORCE China (Sinotruk Ltd.)

1 General information . . . . . . . . . . . . . . . . . . 3 4 TGX, TGS and TGA series . . . . . . . . . . . . . 31

5.4 Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

1.1.1 Content 1.1.3 Technical status

Depending on the severity of the damage, these

1.2.1 Identifying characteristics

As a rule, the vehicle must be described exactly in case

1.2.2 Vehicle identification number

Type plate in the door frame (example TGS)

1.2.3 Vehicle number

1.2.4 Wheel formulae

In hydrostatic front axle drive (MAN HydroDrive), the wheel

Vehicles offered by MAN

Wheel formula Explanation

4x4 Two-axle vehicle with two driven axles "all-wheel drive"

6x2 /2 Three-axle vehicle with non-steered front axles "pusher"

6x2 /4 Three-axle vehicle with steered leading axle

6x2-2 Three-axle vehicle with non-steered trailing axle

6x2-4 Three-axle vehicle with steered trailing axle

6x6 Three-axle vehicle with all-wheel drive

TGS, TGA) and 5.2 (TGL, TGM)

2.1.1 Driver's display and check lamps

The number of lamps may differ, depending on the vehicle

2.1.2 Fault messages

Indications on the driver's display and panel of check lamps,

Indications on the driver's display and panel of check lamps

Driver's display Check lamps Meaning Procedure

Connection between instrument Check fuse.

account situation on road.

Indications on driver's display and panel of check lamps

Driver's display Check lamps Meaning Procedure

Indications on driver's display and panel of check lamps

Driver's display Checklamps Meaning Procedure

Indications on driver's display and panel of check lamps

Driver's display Check lamps Meaning Procedure

Liftgate is open or not fully

Side marking Failure of at least one of left/right- Check fuse.

Indications on driver's display and panel of check lamps

Driver's display Check lamps Meaning Procedure

Indications on driver's display and panel of check lamps

Driver's display Check lamps Meaning Procedure

Red Connection between Check fuses and renew if necessary.

Cooling system Check cooling water system.

Indications on driver's display and panel of check lamps

Driver's display Check lamps Meaning Procedure

Reducing braking power gradually: 3