81.99185-4294_RTL_15_04_TRUCK_ENG.pdf 1 04.05.

2015 13:32:34

81.99185-4294
Text and Illustrations are not binding.
Changes, caused by technical process reserved.

CM

MY

CY

CMY

MAN Truck & Bus AG

Dachauer Strasse 667
80995 München
www.man.eu

Rescue Guide
Truck

MAN Truck & Bus - a company of the MAN group. MAN kann.
1 Imprint

If you have any queries or comments concerning this rescue

guideline, please contact the Technical Documentation
department under the following address:

MAN Truck & Bus AG

Customer & Service Documentation
Dachauer Strasse 667
D­80995 Munich, Germany
Internet: www.man.eu

Copy deadline: 04.2015

We reserve the right to make technical amendments

in the course of further development.

©
2015 MAN Truck & Bus AG

Reproduction, copying or translation of this document in

any form, wholly or in part, requires the written permission of
MAN Truck & Bus AG.
Printed in Germany

Item number
81.99185-4294
2nd edition

1
2 Table of contents

Table of contents 4.6 Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1 Imprint . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Table of contents . . . . . . . . . . . . . . . . 2
3 Preface and safety instructions . . . . . 4
3.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . 5
3.2.2 Handling batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2.3 Exhaust systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2.4 Rescue measures . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2.5 Vehicle windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.6.1 Press front end forwards . . . . . . . . . . . . . . . . . . . . . 41
4.6.2 Door sill section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.6.3 A-column section . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.6.4 Using rescue cylinder . . . . . . . . . . . . . . . . . . . . . . . . 45
4.6.5 Spineboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.7 Driver's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.7.1 Occupant retaining systems . . . . . . . . . . . . . . . . . . 48
4.7.2 Adjust steering wheel . . . . . . . . . . . . . . . . . . . . . . . . 48
4.7.3 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.7.4 Bunks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.7.5 Compartments and drawers . . . . . . . . . . . . . . . . . . 57
4.7.6 Storage boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.8 Trailer/semi-trailer . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.8.1 Unhitching the trailer . . . . . . . . . . . . . . . . . . . . . . . . 60
4.8.2 Uncouple semi-trailer . . . . . . . . . . . . . . . . . . . . . . . . 64

4 Technical rescue . . . . . . . . . . . . . . . . . 8 5 Model overview . . . . . . . . . . . . . . . . 66

4.1 Primary survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Classification and characteristics . . . . . . . . . . . . .66
4.1.1 Arrival at the place of accident . . . . . . . . . . . . . . . . . . 8
5.1.1 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.2 Shut off engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 5.1.2 Axle configuration/wheel configuration . . . . . . . . . . . 67
4.2.1 Pull out ignition key . . . . . . . . . . . . . . . . . . . . . . . . . . 9 5.1.3 Storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.2.2 EMERGENCY-OFF switch . . . . . . . . . . . . . . . . . . . . . 9 5.1.4 Overview of driver's cabs . . . . . . . . . . . . . . . . . . . . . 70
4.2.3 Blow-in CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Illustrations of arrangement . . . . . . . . . . . . . . . . . 71
4.2.4 Interrupt fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2.1 TGL Euro 3-5 chassis . . . . . . . . . . . . . . . . . . . . . . . 71
4.3 Secure and prop-up . . . . . . . . . . . . . . . . . . . . . . . 12 5.2.2 TGL Euro 6 chassis . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3.1 Secure the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 12 5.2.3 TGL Euro 6 tipper . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.3.2 Operate parking brake . . . . . . . . . . . . . . . . . . . . . . . 12 5.2.4 TGM Euro 6 chassis . . . . . . . . . . . . . . . . . . . . . . . . 74
4.3.3 Wheel chocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5.2.5 TGM Euro 3-5 tipper . . . . . . . . . . . . . . . . . . . . . . . . 75
4.3.4 Wheel chocks/-blocks . . . . . . . . . . . . . . . . . . . . . . . 14 5.2.6 TGM Euro 6 tipper . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3.5 Round sling / lashing strap . . . . . . . . . . . . . . . . . . . 16 5.2.7 TGS/TGX 2-axle chassis . . . . . . . . . . . . . . . . . . . . . 77
4.3.6 Lifting / lowering the vehicle . . . . . . . . . . . . . . . . . . . 17 5.2.8 TGS/TGX 2-axle semi-trailer . . . . . . . . . . . . . . . . . . 78
4.3.7 Secure cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5.2.9 TGS/TGX 3-axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.4 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5.2.10 TGS/TGX 4-axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.4.1 Batteries (12 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4.2 Disconnect batteries . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4.3 Mechanical battery main switch . . . . . . . . . . . . . . . . 26
4.4.4 Electric battery breaker . . . . . . . . . . . . . . . . . . . . . . 27
4.5 Access into the vehicle . . . . . . . . . . . . . . . . . . . . . 28
4.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5.2 Rescue platform . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.5.3 Vehicle windows . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.5.4 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.5.5 Side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5.6 Cab rear wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5.7 Vehicle doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5.8 Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.5.9 Roof-mounted air inlet . . . . . . . . . . . . . . . . . . . . . . . 39

2
Experience in Engineered Solutions

Thanks for the support

In preparing this rescue guideline by MAN Truck & Bus AG, the team of WEBER RESCUE system, a leading international
partner for high-quality rescue equipment, played an active and advisory role.
The support, the provision of all rescue equipment and the dedicated work of the instructor staff allowed a detailed
implementation of the subject of truck and bus rescue.
For this pleasant and constructive cooperation, we express our special thanks to the team of WEBER RESCUE Systems.

WEBER RESCUE Systems is also the organiser of the annual RESCUE DAYS, the world's largest training event in the field of
technical assistance.
On three days here, the international WEBER-HYDRAULIK instructor team shall accompany the participants from all over
the world in theory and practice in the rescue of passenger car, truck and bus.

Contact:

WEBER-HYDRAULIK GmbH
Heilbronner Str. 30
74363 Güglingen

Phone: + 49 (0) 7135 / 71-10270

E-mail: info@weber.de
Internet: weber-rescue.com

3
3 Preface and safety instructions
3.1 Preface

This rescue guideline is a manufacturer-specific technical
writing and not a maintenance or repair manual. The design
is intended only for rescue services in their specific field of
application at the scene.
This rescue guideline addresses exclusively left-hand drive
vehicles.
All safety instructions are summarised in a separate chapter
because of a simplification of legibility of the descriptions. This
should provide the opportunity to access specific technical
information in an emergency. The other applicable safety
instructions are preceded by, and to be complied with in
accordance with the respective task.

The rescue guideline contains information from after-sales MAN expressly dissociates itself from claims arising from the
documentation and as such assumes for descriptive example use of information in this rescue guidelines. Since an accident
a technically well-functioning vehicle. Due to external must always be so seen that damages to vehicle parts and
circumstances and the accident as such, these situations electrical and electronic components can not be predicted,
and therefore also the risks for MAN are not foreseeable and their effects can not be definitely foreseen. The measures
are therefore not explicitly described. The descriptions of the applied from this description are therefore always in the obli-
technical measures on MAN vehicles comply with the current gation of the responsible squad leader.
state of the art.
Similarly, the safety instruction and accident prevention MAN Truck & Bus AG
regulations in accordance with the operational requirements Customer & Service Documentation
of the rescue workers are to be complied with. These are not
described in this rescue guidelines.
The procedures and rescue measures shown in this
documentation are carried out in cooperation with rescue
services and only present an option for implementation. For
their application, MAN assumes no liability. These measures
correspond to those techniques and findings applied at
the time of preparation and due to new technologies and
circumstances, any newer experiences are always to be
executed accordingly.

4
3 Preface and safety instructions
3.2 Safety instructions
Security and protection against additional dangers to
occupants and rescue personnel is paramount during
rescue operations. Therefore, the following safety instructions
must be read and followed carefully.
3.2.1 General safety instructions
Risk of burns!
XX Never touch a hot engine with bare hands - risk
of burns!
XX If the engine is at operating temperature, keep
away from the exhaust system as this becomes
hot during vehicle operation and there is a risk of
burns.
XX Hot coolant can be discharged if there are leaks
in the cooling circuit! Maintain a safe distance
and switch off the engine if necessary, otherwise
there is a risk of burns. Eyes and hands could be
injured. Wear suitable protective clothing (safety
goggles, protective gloves).
Risk of accidents and injuries!
If the vehicle is not secured to prevent it from rolling
away, it could begin to move unexpectedly. Persons
could become trapped. Measures must be adopted
to prevent the vehicle from rolling away.
There is a risk of accident and injury when working
at heights. Ensure secure footing on stairs, mobile
ramps etc. Take precautions to prevent falls.
Risk of accidents and injuries!
Only press the emergency­stop switch when the
vehicle is stationary. The vehicle is not ready for
operation if the engine, power­assisted steering,
ABS, transmission etc. have been shut down.
The parking brake must be applied, otherwise
the vehicle could roll away. Persons could fall and
become trapped. Parts of the body could be crushed.
Risk of accidents!
The ECAS system (electronic level control) readjusts
the height level of the vehicle up to 10 minutes after
"ignition". Before the vehicle is raised, disable the
ECAS system.
Do not switch on ignition of the lifted vehicle.
The ECAS system would attempt to regulate the
suspension height of the vehicle.
This may cause the vehicle to slip off the jack or
chassis stand etc., causing severe damages to
people and vehicle.
3.2.2 Handling batteries
Danger of injury!
XX Fire, sparks, naked flames and smoking are
strictly prohibited when handling batteries.
XX Take extra care after prolonged driving or when
charging batteries using a battery charger. The
batteries produce highly explosive oxy-hydrogen
gas - ensure good ventilation.
XX Avoid producing sparks when connecting/
disconnecting electrical consumers or test
instruments directly to/from battery terminals.
XX Batteries contain corrosive acid. Always wear
appropriate protective clothing, protective goggles
and acid-proof rubber gloves.
XX Never tilt batteries. Acid can flow out of the vent
openings.
XX Always wear eye protection when working with
batteries.
XX Switch off all electrical consumers before
connecting or disconnecting batteries. Switch off
the battery disconnection switch.
XX Always disconnect the ground connection (–) first.
XX Avoid short circuits caused by polarity reversal and
by bridging terminals with tools or metal objects.
XX Do not remove terminal covers unless absolutely
necessary.
XX Always connect the ground connection (–) last
when connecting the batteries.
5
3 Preface and safety instructions
3.2 Safety instructions
3.2.3 Exhaust systems
Danger of explosion and fire!
–– Hot exhaust gases are emitted when the engine
is running, and the exhaust system gets very hot.
The exhaust system takes a long time to cool
down.
–– Hot exhaust gases are emitted when the auxiliary
heater is switched on, and the auxiliary heater
exhaust system gets very hot.
Combustible materials, dust and vapours can
be ignited, with the risk of serious injuries and
damages, e.g.:
–– If they are lying on or adhering to the exhaust
system.
–– When refuelling, near fuel, coal, wood or grain
storage facilities or similar.
–– When parking on grassy areas or other vegetated
areas.
–– When parking on hay, straw or greenery.
3.2.4 Rescue measures
–– When loading and unloading dangerous goods
vehicles.
Therefore:
XX Never stop or park the vehicle near combustible
materials, dust and vapours.
XX Never switch on the auxiliary heater near
combustible materials, dust and vapours.
XX Ensure that the auxiliary heater never switches
on automatically near combustible materials,
dust and vapours.
XX Remove flammable materials from the exhaust
system.
XX Ensure that there are no flammable materials
lying on or adhering to the exhaust system.
XX Do not touch hot exhaust systems.
XX Do not remove heat shields or fit underbody
guards onto them.
6
Danger of intoxication!
–– Toxic exhaust gases are emitted when the engine
is running.
–– Toxic exhaust gases are emitted when the auxilia-
ry heater is switched on. There is nowhere for the
exhaust gases to escape in enclosed areas, e.g.
in garages. Inhalation of the exhaust gases can
lead to unconsciousness or death.
Therefore:
XX Never leave the engine running in enclosed areas.
XX Never switch on the auxiliary heater in enclosed
areas.
XX Ensure that the auxiliary heater never switches on
automatically in enclosed areas.
Danger of injury!
When severing of vehicle body parts, sharp cutting
edges may occur.
There is risk of injuries of the occupants and helper.
XX Cover sharp interfaces with suitable protective
covers or column protection.
XX Always use appropriate protective equipment
such as protective clothing, goggles and gloves.
Risk of accidents and injuries!
When working at higher heights, e. g. on the cab
roof, there is a risk of accidents and injury.
XX Ensure secure footing on ladders, rescue plat-
forms etc.
XX Take precautions to prevent falls.
3 Preface and safety instructions
3.2 Safety instructions

3.2.5 Vehicle windows

VSG − Composite safety glass

Danger of injury! Composite safety glass consists of a composite of two or

When cutting/destroying vehicle windows, smallest more superposed sheets of glass with a tear-resistant, elastic
sharp glass particles may occur, which may cause film in between. The film binds the fragments in the case of a
injury to the occupants and rescuers. fracture and impedes the penetration of foreign bodies.
XX Cover occupants with a bright transparent film
(antistatic).
XX Use chip guard. ESG − Toughened safety glass
XX Always use appropriate protective equipment
Toughened safety glass consists of a single disc, which was
such as protective clothing, goggles, gloves and subjected to a special heat treatment. Under high load, it
mouth protection. breaks or disintegrates into small crumbs with no sharp edges.
XX There is a risk of slipping due to glass particles
on the floor. Remove glass particles from the
work area e. g. with broom immediately.

Danger of injury!
Vehicle windows may burst abruptly due to cutting
or deforming adjacent components using cutting
equipment. Here, smallest, sharp glass particles may
occur, which can cause injuries to the occupants
and rescuers.
XX Remove window panes.
XX Cover occupants with a bright transparent film
(antistatic).
XX Use chip guard.
XX Always use appropriate protective equipment
such as protective clothing, goggles and gloves.

7
4 Technical rescue
4.1 Primary survey

4.1.1 Arrival at the place of

accident
Immediately after the arrival at the scene, initial survey is
performed in parallel to protect the accident scene. People
who have had an accident and involved vehicles are
subjected to a first inspection in order to be able to initiate
targeted measures.
This is done taking the following criteria into account:
XX General condition of the persons who have had an
accident:
Is the person conscious/responsive?
Is the person caught or trapped?
XX Assessment of the severity of injuries:
Danger to life?
XX Possibilities of initial access to patients:
Can the doors be opened?
Access through the windscreen, side window, rear wall
cab, roof depending on the location of the vehicle?
XX State of the vehicle under accident:
Stable/unstable position?
XX Is there any risk of fire?
Smoke or running liquids?
XX Leaking service products:
Is there any potential hazard for people and the
environment?
If the service products are sprinkled with binder, the fire
risk is increased at high ambient temperatures due to the
surface extension.
Pay attention to fire safety!
XX Check the tanks for fuel, hydraulic oil and AdBlue®:
Damages/leakages?
Fill level?
XX Assessment of loading and loading securing:
Loading stable/unstable?
Dangerous goods?

8
4 Technical rescue
4.2 Shut off engine

4.2.1 Pull out ignition key

To stop the engine, turn the ignition key to neutral position.
Then pull off the ignition key and secure against reconnection.

0 Insert or remove the ignition key,

Ignition switched off

I Radio position, ignition turned off

II Driving position, ignition switched on

III Starting position

4.2.2 EMERGENCY-OFF switch EMERGENCY OFF switch on the wing panel extension
Deactivating
For certain industrial applications (e.g. dangerous goods
transport vehicles) emergency-stop switches are mounted
in and on the vehicle.
The EMERGENCY OFF switch is located on the instrument
panel and on the outside, e.g. on the wing panel extension
on the driver's side.
It breaks the connection between the batteries and
the electrical system. The EU monitoring device is not
disconnected from the batteries.

XX Open the red security flap 7 upwards.

XX Flick the toggle switch 8 upwards.

9
4 Technical rescue
4.2 Shut off engine

EMERGENCY-OFF switch at driver's place Variant 1

Deactivating

XX Open the red security flap upwards.

XX Flick the toggle switch 10 upwards.

EMERGENCY-OFF switch at driver's place Variant 2

Deactivating

XX Bring the vehicle to a standstill

XX Apply the parking brake

XX Push the red cap upwards

XX Press the top of the rocker switch

All loads are disconnected from the vehicle electrical system,

with the exception of the EU monitoring device.

10
4 Technical rescue
4.2 Shut off engine

4.2.3 Blow-in CO2

The engine can be turned off by blowing CO2 into the air
intake. The CO2 causes a reduction of the oxygen content
in the intake air. Due to this lack of oxygen, the fuel-air mixture
is no longer ignitable.
XX Pull the bellows off the air intake upwards.

XX Blow CO2 intermittently in the resulting opening.

XX Continue or repeat until the engine stops operation.

Air intake left, on the example of TGX

The CO2 escapes at a temperature of –78 °C, as snow in
parts. There is a risk of your hands freezing.
When using a CO2 extinguisher to shut down the engine, pay
attention to protection against cold and eye protection.

Air intake right, on the example of TGS

4.2.4 Interrupt fuel supply

To interrupt the supply of fuel to the engine, the fuel line is
disconnected from the tank to the engine with a suitable tool.
It should be noted that in the fuel line between the tank and
engine, residual fuel is sufficient and that the motor is still
running after considerable time until standstill. Therefore,
the fuel supply should be interrupted only when necessary
depending on the situation of rescue.

Blow-in CO2

11
4 Technical rescue
4.3 Secure and prop-up

4.3.1 Secure the vehicle

In order to carry out the necessary rescue measures quickly
and safely, the vehicle must be secured by appropriate means
to prevent rolling, tilting or other movements. When attaching
tools to secure and stabilise the vehicle, make sure that the
following rescue measures are not made more difficult or
obstructed in the process.
The securing type of the cab depends on the type of vehicle
(high roof, cab with sleeper compartment, etc.). The different
variants are shown, one of which is normally sufficient.

4.3.2 Operate parking brake

The parking brake acts mechanically on the wheels of the rear
axle(s) by spring force when the spring-loaded brake cylinders
are vented. In the case of a pneumatic front axle parking
brake, the brake acts on the wheels of the front axle.
XX Push the lever 1 backwards until it engages

The parking brake is applied when the lever can no longer be

moved forwards without pulling the lever lock 2.

Parking brake (exemplary image)

1 Lever

2 Lever lock

12
4 Technical rescue
4.3 Secure and prop-up

4.3.3 Wheel chocks

The vehicle is secured with two wheel chocks on the rear axle
to prevent rolling away.
A wheel chock is there depending on model and design
–– Left storage locker
–– Under the passenger seat
–– Rear left on the frame

Wheel chock (on the example of TGX tractor unit)

Rear axle secured with wheel chocks

13
4 Technical rescue
4.3 Secure and prop-up

4.3.4 Wheel chocks/-blocks Series TGL and TGM

For supporting with chocks or blocks, the application points

for the jack are suitable.

Rear axle with leaf spring suspension

Rear axle with air suspension

Front axle with leaf-spring suspension, non-driven

14
4 Technical rescue
4.3 Secure and prop-up

Series TGX, TGS and TGA

Front axle with air suspension, non-driven Tandem rear axle with leaf-spring suspension

Driven front axle Rear axle with air suspension

Rear axle with leaf spring suspension Automatic liftable trailing / leading axle

15
4 Technical rescue
4.3 Secure and prop-up

4.3.5 Round sling / lashing strap

When attaching round slings or load restraint assemblies
for securing the vehicle, it is to be noted that the force is
introduced via suitable points on the vehicle:
–– Spring pivot points
–– Rear crossbeam
–– Towing eyes at the front (vehicles with plastic bumpers)
–– Coupling jaw at the front (vehicles with steel bumper)
–– Trailing arm chock, directly on the frame

As these components are not unlimitedly capable of being

loaded, the force introduction should be via as many and
evenly distributed points.

Rear cross member of a tractor unit

Examples

Towing eyes at the front, screwed on both sides XX Turn (unlock) the pin 2 clockwise

XX Pull out the pin 2

XX Insert the tow bar into the coupling mouth 3

XX Insert the pin 2

The towing eyes are not mounted on the vehicle. In
the bumper, there are two mounting threads for towing eyes.
A towing eye is supplied from the factory for each vehicle. It is
located in the storage box on the left side; in vehicles without
storage box in the vehicle interior, in the tool kit behind the
driver's seat.
XX Remove the cover over the adapter thread on the bumper

XX Screw in the towing eye until it stops.

16
4 Technical rescue
4.3 Secure and prop-up

4.3.6 Lifting / lowering the vehicle

Electronically controlled air suspension (ECAS)
The air suspension enables the lowering or raising of the
vehicle frame, e.g., for loading and unloading.
To do this, the ignition must be switched on and there must
be adequate compressed air available. The suspension travel
depends on the type of vehicle.
The following versions are possible:
–– Leaf/air suspension: There is only air suspension on the
rear axle(s)
–– Air/air suspension: Front and rear axles have air suspension

When the ignition is switched on, the frame is raised or

lowered to the height that was set when the ignition was last Example operating unit of air-air suspension
switched off. 1 Raising the vehicle frame
The frame height (level) is programmed and set using the 2 Lowering the vehicle frame
control unit installed in a holder on the side of the console for
3 Setting or saving level 1
the driver’s seat.
4 Setting or saving level 2

5 Pre-selecting vehicle frame at front

6 Check lamp for vehicle frame at front

7 Check lamp for vehicle frame at rear

8 Pre-selecting vehicle frame at rear
After removing the battery main switch or 9 Setting the ride height
disconnecting the battery, ECAS is disabled.
10 "STOP" button

Pressing the "STOP" button stops any control
procedure (raising, lowering and readjusting) immediately.
The level reached is kept constant.

Example, arrangement of operating unit

17
4 Technical rescue
4.3 Secure and prop-up

4.3.7 Secure cab

The cab can be subject to uncontrolled movement during
rescue work.
Therefore, it is necessary to secure the cab with lashing
strap. The straps are to fasten in such a way that subsequent
rescue operations are not hindered.

Round sling and lashing strap over the front axle

XX Wrap the round sling on the right and left around the front
axle and pull it upwards.
XX Attach lashing strap on one side with ratchet with eye hook
on the round sling.
XX Attach lashing strap on the other side with eye hooks on
the round sling.
XX Throw lashing strap over the cab.

XX Mount the lashing strap into the ratchet and clamp securely.

XX Secure ratchet.

Secure cab, example of TGS.

18
4 Technical rescue
4.3 Secure and prop-up

Lashing strap on storage compartment hatch and front

wheel

XX Open storage compartment hatch by actuating the unlocking

mechanism in the cab on the rear wall behind the seat.
Or if not accessible
XX Storage compartment hatch at the bottom, e.g. bend using
a wooden wedge, and pry open with halligan tool.
XX Attach the lashing strap with ratchet in the latch opening of
the storage compartment hatch.
XX Hook rim hooks into the rim.

XX Attach lashing strap with eye hook.

XX Mount the lashing strap into the ratchet and clamp

securely.
XX Secure ratchet.

Unlocking mechanism of the storage compartment hatch

Secure the cab via storage compartment flap using the

example of TGX

19
4 Technical rescue
4.3 Secure and prop-up

lashing strap in the side wall and front wheel

XX Remove plastic cover of the air intake with halligan tool.

XX Cut an opening up into the side wall with the cutter.

XX Alternatively you can punch a hole in the side wall with a

halligan tool. Then expand the hole until a rim hook can be
hooked in.
XX Hook rim hook.

XX Attach lashing strap with eye hook.

Remove cover of air intake

Cut in side wall.

Attach the lashing strap

20
4 Technical rescue
4.3 Secure and prop-up

XX Hook rim hooks into the rim.

XX Fasten lashing strap with eye hooks using ratchet.

XX Mount the lashing strap into the ratchet and clamp

securely.
XX Secure ratchet.

Attach the lashing strap to the wheel

21
4 Technical rescue
4.3 Secure and prop-up

Load restraint assembly from the rear cab wall to

the frame

XX Fasten lashing strap with eye hooks to the attachment

points of the rear cab wall.
XX Guide lashing strap crosswise to the frame to left and right.

XX Hook rim hooks into the retaining device of the side

underride protection.
XX Fasten lashing strap with eye hooks using ratchet.

XX Fasten lashing strap with eye hooks above the tread of

the side underride protection.
XX Clamp lashing straps securely with ratchet.

XX Secure ratchets.

22
4 Technical rescue
4.3 Secure and prop-up

Safety and rescue struts

XX Install rescue struts at an angle of about 45 ° to the cab.

XX Adjust required length by pulling out the telescopic arm.

XX Ensure firm footing.

XX Ensure sufficient lateral distance to the door.

XX Hook rim hooks into the rim.

XX Attach lashing strap with eye hook.

XX Clamp lashing strap securely with ratchet.

XX Secure ratchet.

23
4 Technical rescue
4.4 Power supply

4.4.1 Batteries (12 V)

The on-board voltage is generally 24 V. There are two
batteries of 12 V installed.

Two variants are possible depending on the model:

–– Vehicle batteries side by side
–– Vehicle batteries on top of one another (compact battery
box) in TGS and TGX

Vehicle batteries one beside another (example)

1 Minus terminal
2 Plus terminal
3 Battery bridges

Vehicle batteries one under another (example)

1 Cover of the battery box
2 Bayonet catch
1

4.4.2 Disconnect batteries

First, open the battery box to disconnect the batteries.

Batteries one beside another

XX Open bayonet catch 1.

XX Remove the cover from the battery box.

24
4 Technical rescue
4.4 Power supply

Batteries one above another

XX Open catch 1.

XX Fold the frame 2 forwards.

XX Push the cover 3 backwards and remove it upwards.

XX Unscrew electrical line on ground connection (negative

terminal) of the battery and prevent it from re-contacting.

When disconnecting the battery, first disconnect
the ground connection (negative terminal). Alternatively, the
connecting line (battery bridge) can be severed. Make sure
that the cutting tool does not come into contact with any
metal parts of the vehicle, there is a danger of short-circuiting.

Batteries one beside another

XX Open clamping bracket 1 on the battery box.

XX Remove the cover 2 from the battery box.

Or
XX Open the battery box bayonet locks 3.

XX Remove the cover 2 from the battery box.

25
4 Technical rescue
4.4 Power supply

4.4.3 Mechanical battery main

switch
The mechanical battery main switch breaks the connection
between the batteries and the electrical system of the engine.
The mechanical battery main switch is located on the front or
the bottom of the battery box.

Deactivating
XX Switching off the ignition.

XX Pull off the ignition key and secure against reconnection.

XX Remove the protective cap 1 from the main switch.

XX Attach the lever 2 and turn it clockwise up to the stop.

Mechanical battery main switch (example TGX)
XX Pull lever 2 and insert cap 1 again into the power switch.
1 Protective cap
2 Lever

Mechanical battery main switch (example TGL/TGM)

1 Protective cap
2 Lever

26
4 Technical rescue
4.4 Power supply

4.4.4 Electric battery breaker

The electrical battery breaker breaks the connection between
the batteries and the electrical systems of the engine.
This happens about 35 seconds after the switch is actuated
or as soon as the auxiliary heater power off delay is over and
the auxiliary heater has switched off.

Deactivating
XX Press the switch downwards.

The switch springs back to the neutral position.

Electric battery breaker (example of TGX)

The mechanical battery main switch and the electrical battery
isolation switch disconnect only the electric systems of the
batteries located on the engine. Components located inside
the cab such as interior lighting, door modules and radio
are not disconnected. For voltage disconnection of the
entire vehicle, therefore, the battery must be disconnected
necessarily.

27
4 Technical rescue
4.5 Access into the vehicle

4.5.1 General
The operations described below are presented in
chronological order.
A temporally parallel work of emergency services (survey
and primary care) and fire brigade (technical rescue) can
significantly shorten the process duration until relieving the
patient.
To enable parallel works of emergency services and fire
brigade, therefore, multiple access ports should be created.

4.5.2 Rescue platform

The rescue platform provides ample space and secure base
for working above floor level. So that the subsequent rescue
operations are not hindered, e.g. when opening the doors, the
height of the rescue platform must be set accordingly. Rescue platform (example)

Building the rescue platform:

XX Measure the distance from floor to lower edge of the
driver's door (without lining the entrance steps).
XX Build rescue platform and adjust the height accordingly.

28
4 Technical rescue
4.5 Access into the vehicle

4.5.3 Vehicle windows

When removing vehicle windows, the following is to be
observed:
XX Protect occupants in the vehicle with bright transparent film
(antistatic) against glass splinters.
XX Use chip guard.

XX Remove glass residues with protective gloves.

XX Remove glass residues on the ground immediately from the

work area (e.g. push under the vehicle), otherwise there is a
risk of slipping.

Splinter guard

4.5.4 Windscreen
The windscreen consists of composite safety glass (VGS) and
is glued into the frame.
Composite glass panes can be cut or cut out using a glass
saw.
XX Hit the opening in the pane.

XX Cut the pane along the frame above and on the sides.

Hand saw

Electric saw

29
4 Technical rescue
4.5 Access into the vehicle

XX Fold window pane downwards.

XX Cover folded pane with protective cover.

XX Remove rescue platform.

XX Position and secure scaling ladders.

If the pane is completely excised, it must be secured against

falling. Here, the relatively high weight of truck windscreens
has to be considered.

Fold window pane downwards

Secure with protective cover

Set up scaling ladder

30
4 Technical rescue
4.5 Access into the vehicle

4.5.5 Side windows

The side window panes consist of toughened safety glass
(ESG) and are removed by the spring peening tool.

Door on driver's and co-driver's side

XX Stick adhesive foil or tape on the pane as completely as
possible, provided that the time required with regard to the
type of injuries or the injury pattern is acceptable.
XX For panes that are accessible from inside for rescue
workers (e.g. on the co-driver's side.):
Here, the chip guard can be pressed against the pane from
the inside.
XX By using the spring peening tool in the right or bottom left Mask the window pane
corner, the window shatters into small items that remain
glued to the adhesive film or the adhesive tape.
XX Remove pane outwards.

XX Remove glass residues along the window seal with

protective gloves.

Remove pane outwards

Use the chip guard

31
4 Technical rescue
4.5 Access into the vehicle

XX Alternative option: Crank or pull down the side windows,

cover and destroy using spring peening tool.

Alternative: Lowered side window

Rear side window

XX To protect the occupants of the vehicle, a curtain can be
hung against the side window in the driver's cab.
XX Use spring peening tool in the right or lower left corner -
the pane shatters into small items.
XX Remove pane outwards.

XX Remove glass residues with protective gloves.

Use protective gloves

Use protective gloves

32
4 Technical rescue
4.5 Access into the vehicle

4.5.6 Cab rear wall

In cases where an access through the front of the vehicle is
not possible, it can be accessed via the cab rear wall.
XX Saw a section with the sheet saw in the cab rear wall.

XX Bend the section downwards.

XX Fold soundproof matting downwards.

XX Pull out the interior panelling outwards with the halligan tool
and fold downwards.

Saw the section in the rear wall

Before incision in the cab rear wall, check the interior, and in
particular for any existing sleeper-cab.

Bend the section downwards

Fold soundproof matting downwards

33
4 Technical rescue
4.5 Access into the vehicle

4.5.7 Vehicle doors

Before setting up the rescue platform, the lower door interior
cladding of the entrance steps, if any, is removed.
XX Saw off the door interior cladding along the bottom edge of
the door with the electric handsaw.

Saw off door interior cladding

The cutting edge serves as a standard gauge for the height of

the rescue platform, so that the door can be freely opened or
spread apart.
Set up rescue platform and align parallel to the door.
The work surface should end about a hand's breadth behind
the door.

Cut edge of door interior cladding

34
4 Technical rescue
4.5 Access into the vehicle

Remove claddings
In order to expose the door hinges, the appropriate cladding
components must be removed.
XX Remove A-column cladding with the halligan tool.

XX Remove side parts of the front panel and air deflectors with
the spreader; in doing so, use the spreader from above.
XX Remove parts of cladding insofar as the two door hinges
are exposed.

Remove A-column cladding

Remove air deflectors

Top door hinge

35
4 Technical rescue
4.5 Access into the vehicle

Bottom door hinge

Secure the door to prevent it from dropping down

Due to the heavy weight, the cab doors must be secured
with the fire brigade line against falling.
XX Spread the door upwards.

XX Fasten fire brigade line to the door frame.

Spread the door upwards

Spread the door upwards

36
4 Technical rescue
4.5 Access into the vehicle

XX Secure the door from the opposite side of the vehicle with
the fire brigade line.

Secure door

Unscrew door hinges

If it is possible in the accident situation and vehicle condition,
the hinges of the doors can be unscrewed.
XX Select matching socket wrench insert.

XX Unscrew and remove four screws per hinge at the

A-column using a socket wrench, possibly with extension.
XX Lower the door with fire brigade line securely and remove
to the side.

1 Screws on the top side of door hinge

2 Screws on the bottom side of door hinge

37
4 Technical rescue
4.5 Access into the vehicle

Spread door
If there is no way to unscrew the hinges, the door must be
spread using the spreader on the hinge side.
XX Set the spreader above the respective hinge between
the A-column and door frames.
XX Spread door until the hinge breaks away from the door
frame.
XX Lower the door with fire brigade line securely and remove
to the side.

Spread door

Alternatively, hinges may be severed or cut with heavy-duty
scissors.

Remove door

38
4 Technical rescue
4.5 Access into the vehicle

4.5.8 Sunroof
The sunroof is operated with the rocker switch on the centre
console.

Tilting and opening the roof

XX Lift ledge 1 to open the insect screen and push backwards.

XX Press the rocker button downwards until the roof has been
raised to its end position.
XX Release the rocker button.

XX Press the rocker button downwards again until the roof has
reached the required position.

1 Ledge of insect screen

Rocker switch of sunroof (example of TGX)

4.5.9 Roof-mounted air inlet

Open the roof-mounted air inlet from inside
The roof-mounted air inlet is mechanically operated.

Unlocking
XX Swivel the bar 1 on the roof-mounted air inlet downwards.

Opening
XX Push up the hatch.

1 Bracket

39
4 Technical rescue
4.5 Access into the vehicle

Open the roof-mounted air inlet from outside

XX Position and secure scaling ladder.

XX While staying on the roof, self-safety must be observed.

XX Open the roof-mounted air inlet with halligan tool and/or

spreader.

Open roof-mounted air inlet with halligan tool

When working on the cab roof, there is a risk of falling.

Corresponding regulations and measures for self-protection
should be followed.

Spread roof-mounted air inlet

40
4 Technical rescue
4.6 Relief

4.6.1 Press front end forwards

If the vehicle is accidentally deformed to the extent that the
driver/passenger is trapped between the dashboard and seat,
the front end must be pushed forward accordingly.

Depending on the condition of the vehicle, the rescue cylinder

can be used without prior relief cuts on side sills and/or
A-column due to time related reasons in order to produce the
required opening for relieving the patient.
Press side sill together

4.6.2 Door sill section

In order to make the necessary cuts in the side sills, the sill
must first be pressed together using the spreader.
XX Fix spreader on side sills and push as far as possible
towards the centre of vehicle.
XX Press side sill together.

XX Repeat procedure at intervals of about 20 cm.

XX Mark required cuts on the sill.

Press side sill together

Marking the cuts on the sill

41
4 Technical rescue
4.6 Relief

XX Cut side sills in v-shape:

With the rescue shears, cut diagonally from behind
and then cut diagonally from the front. The angle of the
V-section must be so chosen that the rescue shears can
be guided into the cut-out.
XX Run rescue cutter into the cut-out and run further cut in the
cab floor toward interior. Cut only as much as the position
of the patient allows it.

V-section: Cut diagonally from behind

V-section: Cut diagonally from the front

Incision on cab floor

42
4 Technical rescue
4.6 Relief

4.6.3 A-column section

XX Mark section at an angle of about 45 ° in the upper third of
the A-column.
XX Cut through A-column using the rescue shears diagonally
upwards rising from the inside outwards.
Due to the oblique cut, it is prevented that the cut surfaces
tilt forward when pressing the A-column. In addition,
the A-column cannot spring back to the rear during the
subsequent removal of the rescue cylinder.

Marking of the section on the A-column

Section of A-column

Section of A-column

43
4 Technical rescue
4.6 Relief

XX Mark additional sections e.g. on the handles.

XX Separate handle on A- and B-column at the top and

bottom respectively using the rescue shears.

The separation of the handles is necessary in order to attach

the rescue cylinder on A- and B-column unhindered.

Remove handle

XX Cover cut edges and -surfaces with column protection or

protective covers.

Column protection / protective cover

44
4 Technical rescue
4.6 Relief

4.6.4 Using rescue cylinder

XX Remove rotating door seal in order to provide appropriate
support surfaces for the rescue cylinder.
XX Measure the distance between A- and B-column and select
appropriate rescue cylinder.
XX Set the rescue cylinder between the A-and B-column at
about the level of the door lock. If the B-column does not
allow any sufficiently secure supporting surface due to
accidental deformations, a sill set is used for positioning
the rescue cylinder. Upon extension of the rescue cylinder,
it should be ensured that the sill support does not slip or
tilts sideways.
Rescue cylinder with sill set
XX Extend rescue cylinder until the front end is pushed as far
as necessary forwards.

Rescue cylinder without sill set

45
4 Technical rescue
4.6 Relief

In order to create the necessary space for relieving the

patient, the horizontally deployed rescue cylinder must be
removed again.
To relieve the load, a second rescue cylinder should be
inserted vertically between the cockpit cross member and the
roof frame at the level of the steering wheel.
XX Set the rescue cylinder at the bottom through the steering
wheel on the combined instrument.
XX Set the rescue cylinder at the top on the roof frame.

XX Extend the rescue cylinder until the required height is

reached.
XX Remove horizontal rescue cylinder.

Rescue cylinder for windscreen

46
4 Technical rescue
4.6 Relief

4.6.5 Spineboard
If all medically necessary measures are carried out, the
patient is rescued with the spineboard (rescue board) from
the vehicle. Procedure and pace are determined by the
emergency doctor / rescue service.
XX Fold railings of the work platform downwards or dismantle
(depending on model).
XX Push the spineboard at the height of the seat in the vehicle.

XX Raise patient on the spineboard and secure.

XX Pull the spineboard from the cab and place on the work
platform.
XX Transport the patient away for further medical care. Push spineboard into the vehicle

Transporting away

47
4 Technical rescue
4.7 Driver's cab

4.7.1 Occupant retaining systems

Seat belt
All series are equipped with 3-point seat belts for driver and
co-driver.

4.7.2 Adjust steering wheel

Series TGX and TGS
There must be sufficient reservoir pressure in the
compressed-air system in order to adjust the steering wheel.
XX Press rocker switch upwards and hold.

XX Set the height and reach of the steering wheel

XX Release the rocker button.

The steering wheel is locked after approx. 5 seconds.

Adjust steering wheel rocker switch

48
4 Technical rescue
4.7 Driver's cab

Series TGA, TGL and TGM

There must be sufficient reservoir pressure in the
compressed-air system in order to adjust the steering wheel.
XX Push down and hold push button 9 on the driver's seat
console.
XX Set the height and reach of the steering wheel

XX Release the push button 9

The steering wheel is locked.

9 Push button

49
4 Technical rescue
4.7 Driver's cab

4.7.3 Seat
For all series, there are three seating variants to choose
from. In the following examples, the maximum equipment is
described in each case.

Static seat, Grammer

Controls

1 Setting the seat surface angle

2 Setting the backrest angle

3. Setting the seat surface height

4. Setting the lengthwise position (fore/aft)

50
4 Technical rescue
4.7 Driver's cab

Air-cushioned comfort seat, Grammer

Controls
1 Setting the seat surface angle

2 Setting the arm rests

3 Setting the backrest angle

4. Setting the seat surface height

5 Setting the vertical damper (soft/hard)

6 Entry and exit aid (quick-lowering facility)

7 Setting the reclined position

8. Setting the lengthwise position (fore/aft)

51
4 Technical rescue
4.7 Driver's cab

Air-cushioned comfort- and luxury seat, Isringhausen

Controls
1 Setting the seat surface angle

2 Setting the depth of the seat cushion

3 Setting the horizontal cushioning

4 Setting the arm rests

5 Setting the angle of the top part of the backrest

6 Setting the backrest angle

7 Setting the lumbar support and lateral support

8. Setting the seat surface height

9 Setting the vertical damper (soft/hard)

10 Entry and exit aid (quick-lowering facility)

11 Setting the reclined position

12. Setting the lengthwise position (fore/aft)

52
4 Technical rescue
4.7 Driver's cab
Example for maximum adjustment paths of the steering
wheel and driver's seat (example of TGX)
a Distance/height of steering wheel from driver
b Distance of seat to instrument panel
c Seat height
Settings:
–– Steering wheel is in distance/height all the way
backwards or down
–– Seat in longitudinal direction all the way forward
–– Height of the seat area all the way upward
a Distance/height of steering wheel from driver
b Distance of seat to instrument panel
c Seat height
Settings:
–– The reach / height of the steering wheel is completely to
the front or up
–– Seat in longitudinal direction all the way backward
–– Height of the seat area all the way downward
53
4 Technical rescue
4.7 Driver's cab

Co-driver's seat and-centre seat (TGL/TGM)

The seat positions the individual seats of the co-driver's
seat for 2 persons and the co-driver's centre seat are not
adjustable.
The backrest of the middle seat of the seat and the individual
middle seat can be folded forward as writing surface, bottle
holder and stairs can be used for the bunks.

Fold backrest
XX Push the lever 1 backwards.

XX Fold backrest forwards until you hear it engage.

Fold up seats
XX Raise front seats.

1 Lever

54
4 Technical rescue
4.7 Driver's cab

4.7.4 Bunks
Models with long cab are equipped with one or two bunks.

Bottom bunk

Folding up
XX Fold the lever 1 upwards.

XX Press button 5 and while doing so, swivel safety rail

4 downwards.
XX Swivel the bunk until the stop is reached.

XX Fold the lever 1 downwards.

XX Release the bunk.

1 Lever

4 Safety rails

5 Button

55
4 Technical rescue
4.7 Driver's cab

Top bunk

Folding up
XX Press the button 7 upwards.

XX Pull the restraint net downwards.

XX Swivel the bunk upwards.

XX Press the buckle latch into the belt catch 6 until you hear it
engage.

7 Button

6 Buckle

56
4 Technical rescue
4.7 Driver's cab

4.7.5 Compartments and drawers

In the centre console, there is the ashtray compartment and
one or two drawers.

6 Ashtray compartment

7 Drawer

All series
The high-roof cabins are equipped with storage
compartments above the windscreen.

9 Storage compartment

57
4 Technical rescue
4.7 Driver's cab

Refrigerator compartment
The cooler is located between the seats.
It is equipped with a battery discharge protection.
This switches off the cooler automatically to protect
the battery before the voltage is no longer sufficient
for starting the vehicle.

Moving the refrigerator compartment

XX Pull adjusting bracket 1 up, while pushing the cooler
forward or backward.
XX Make sure you can hear the refrigerator compartment
engage.

1 Adjustable stays

58
4 Technical rescue
4.7 Driver's cab

4.7.6 Storage boxes

The long cabs are each equipped with a storage box on
the right and left.

Open flap outwards

The unlocking tool handle 1 for the storage box flap 2 is
located behind the driver or passenger seat.
XX Draw unlocking tool handle 1 - the storage box flap
2 jumps up.
XX Push the lever under the storage locker flap 2 upwards
with your finger in the direction of the arrow 3.
XX Swivel the storage locker flap 2 upwards.
1 Unlocking tool handle

The storage locker on the driver's side is also accessible from

inside the cab.

Open flap inwards

XX Push the driver's seat forwards,.

XX Fold lower bunk upwards.

XX Swivel the cover 4 upwards.

2 Storage box flap

4 Cover

59
4 Technical rescue
4.8 Trailer/semi-trailer

4.8.1 Unhitching the trailer

XX Depending on the accident situation, it may be necessary
to unhitch the trailer or the semi-trailer from the tractor to
allow unhindered access to the rear of the cab.

Unhitching the trailer

Trailer couplings with control pin – Rockinger and

Ringfeder
The coupling can only be opened when the coupling jaw is in
the middle position or the side end positions.

XX Use the parking brake and/or chocks on the rear wheels

to prevent the trailer from rolling away. See the operating
instructions provided by the trailer manufacturer.
XX Fix the trailer drawbar.

XX Remove the cable connectors for the trailer brakes, lighting

and power supply from the sockets.
XX First disconnect the reservoir line coupling head (red).

XX Disconnect the brake line coupling head (yellow).

XX Push the manual lever 2 until it locks into place.

XX Do not stand in the area between the tractor and trailer.

XX Carefully drive the tractor forwards until the drawbar eye

has left the trailer coupling.
Moving the drawbar eye out of the coupling jaw 4 causes the
coupling pin 3 to be raised and unlocked. It falls down into
the drawbar eye and closes the trailer coupling.

60
4 Technical rescue
4.8 Trailer/semi-trailer

Operating elements of the trailer coupling of the brand

Rockinger
Types described here: RO 42, RO 400, RO 263, RO 500,
RO 430
1 Control pin
2 Hand lever
3 Coupling pins
4 Coupling jaw

Operating elements of the trailer coupling of the brand Ringfeder

Types described here: 4040, 4045, 5050, 5090
1 Control pin
2 Hand lever
3 Coupling pins
4 Coupling jaw

61
4 Technical rescue
4.8 Trailer/semi-trailer

Trailer coupling with check pin – Rockinger RO 56 E

The coupling can only be opened when the coupling jaw is in
the middle position or the side end positions.

1 Control pin

2 Hand lever

3 Coupling pins

4 Coupling jaw

XX Use the parking brake and/or chocks on the rear wheels to

prevent the trailer from rolling away.
XX Fix the trailer drawbar.

XX Remove the cable connectors for the trailer brakes, lighting

and power supply from the sockets.
XX First disconnect the reservoir line coupling head (red).

XX Disconnect the brake line coupling head (yellow).

XX Pull the hand lever 2 downwards until it engages.

XX Do not stand in the area between the tractor and trailer.

XX Carefully drive the tractor forwards or pull the trailer

backwards until the drawbar eye has left the trailer
coupling.

Moving the drawbar eye out of the coupling jaw 4 causes the
coupling pin 3 to be raised and unlocked. It falls down into
the drawbar eye and closes the trailer coupling.

62
4 Technical rescue
4.8 Trailer/semi-trailer

Low-mount coupling system Ringfeder 5055AW

The coupling can only be opened when the coupling jaw is in
the middle position or the side end positions.
XX Use the parking brake and/or chocks on the rear wheels
to prevent the trailer from rolling away. See the operating
instructions provided by the trailer manufacturer.

XX Fix the trailer drawbar.

XX Remove the cable connectors for the trailer brakes, lighting

and power supply from the sockets.
XX First disconnect the reservoir line coupling head (red).

XX Disconnect the brake line coupling head (yellow). 1 Control pin

XX Remove safety catch 5. 2 Hand lever
XX Press hand lever 2 via the pressure point outwards until it
3 Coupling pins
engages.
4 Coupling jaw
XX Do not stand in the area between the tractor and trailer.
5 Safety catch
XX Carefully drive the tractor forwards until the drawbar eye
has left the trailer coupling.

Moving the drawbar eye out of the coupling jaw 4 causes

the coupling pin 3 to be raised and unlocked. It falls down
into the drawbar eye and closes the trailer coupling.
XX Push back hand lever 2 inwards until it stops.

XX Closing the trailer coupling manually

XX Attach safety catch 5

XX Check whether the trailer coupling is closed fully.

63
4 Technical rescue
4.8 Trailer/semi-trailer

4.8.2 Uncouple semi-trailer

Before uncoupling, the semi-trailer must be secured against
rolling away with wheel chock and by applying the parking
brake.
Usually there are two wheel chocks in a holder on the left rear
of the frame of the semi-trailer.

XX Remove the wheel wedges from the holder.

Wheel wedges for the semi-trailer

XX Place wheel chocks at the rear wheel of the rearmost axle.

Secure with wheel wedges

Parking brake of semi-trailer

The parking brake of the semi-trailer is on the rear left side of
the frame of the semi-trailer behind the rearmost axle.
XX Pull the red button of the parking brake outwards.

Apply the parking brake

64
4 Technical rescue
4.8 Trailer/semi-trailer

Disconnect supply lines

After securing the trailer, the supply line between the semi-
trailer and the tractor is separated.
XX Remove the cable connectors for the trailer brakes, lighting
and power supply from the sockets.
XX First disconnect the reservoir line coupling head (red).

XX Disconnect the brake line coupling head (yellow).

Disconnect supply lines

Lower leg supports

The crank lever is located on the right leg support of the
semi-trailer.
XX Unhinge the crank lever from its holder and swivel outwards.

XX Turn crank lever clockwise and lower the leg supports until
the end position.
XX Fold the crank lever.

Once the leg support have reached the bottom, the gear ratio
can be changed by applying slight pressure of the crank lever
in the direction of the axis of rotation. This reduces the effort.

Lower leg supports

Unlock fifth-wheel coupling

Unlocking mechanism is located on right side on the fifth-
wheel coupling
XX Press unlocking mechanism forward.

XX Pull unlocking mechanism outwards until it stops.

XX Carefully drive up with the tractor vehicle or pull the semi-

trailer backwards.

Unlocking mechanism of the fifth-wheel coupling

65
5 Model overview
5.1 Classification and characteristics

5.1.1 Series
The MAN Trucknology®-vehicle programme comprises
the series
TGL (7.5 – 12 t) as chassis and tipper
TGM (12 – 26 t) as chassis and tipper
TGS (18 – 41 t) as semi-trailer, chassis and tipper
TGX (18 – 41 t) as semi-trailer and chassis

Example TGL (tipper) Example TGM (chassis)

Example TGS (chassis) Example TGX (semi-trailer)

66
5 Model overview
5.1 Classification and characteristics

5.1.2 Axle configuration/wheel

configuration
Series
TGL TGM TGS TGX
7.5 – 12 t 12 – 26 t 18 – 41 t 18 – 41 t
R Chassis Tipper Chassis Tipper Semi-trailer Chassis Tipper Semi-trailer Chassis

4x2 þ þ þ þ þ þ þ þ þ
4x4 þ þ þ þ þ
6x2*) þ þ þ þ þ
6x2**) þ þ þ
6x4 þ þ þ þ þ þ þ
6x4*) þ þ
6x6 þ þ þ
8x2*) þ
8x4 þ þ
8x4* )
þ þ þ
8x4**)
8x6 þ þ
8x8
*) with trailing axle
**) with leading axle
R = wheel configuration (number of wheels x number of driven wheels)

67
5 Model overview
5.1 Classification and characteristics

5.1.3 Storage tank

TGL TGM TGS TGX

Diesel 100 to 200 litre 200 to 910 litre

Reducing agent 10 litres 20 litres 24 to 100 litre
(AdBlue )®

Hydraulic oil 150 to 200 litre

Examples for arrangement/configuration of the tanks

Fuel tank on right side / AdBlue®-Tank on left side Fuel tank and AdBlue® tank on right side

Combi-tank of fuel and AdBlue® Combi-tank of fuel and hydraulic oil

4 Filler neck for fuel

5 Filler neck for reducing agent on vehicle with AdBlue®
6 Filler neck for hydraulic oil

68
5 Model overview
5.1 Classification and characteristics

Dual-tank system
In the MAN dual-tank system, both fuel tanks are connected
with a connecting tube at the height of the tank bottom edge.
A threaded neck is welded to both tanks. A GE union forms
the connection to the shut-off valve, which should prevent the
complete leakage of fuel in case of damage or separation of
the connecting tube.
These shut-off valves can also be operated manually and
used as shut-off device.

Dual-tank system with shut-off valve (schematic)

1 Fuel tank

2 Connecting tube

3 Bracket

4 Clamp

5 Shut-off valve

69
5 Model overview
5.1 Classification and characteristics

5.1.4 Overview of driver's cabs

C M L LX

575
923

1665
1240

1385

1925

590
1385

1645
1569

1645
2240
2240

2240
2240

1620 1880 2280 2280

XL XLX XXL DoKa* )

740
580

2100
1025

2200
1875

1385
1975

1620
790
690
1560

1645
1660
2440

2440

2440

2240

2280 2280 2280 2785

Dimension in mm
*) Crew cab

70
5 Model overview
5.2 Illustrations of arrangement

5.2.1 TGL Euro 3-5 chassis

B Battery

K Fuel tank

N EMERGENCY-OFF switch

T Battery main switch

71
5 Model overview
5.2 Illustrations of arrangement

5.2.2 TGL Euro 6 chassis

AB AdBlue® tank

B Battery

K Fuel tank

N EMERGENCY-OFF switch

T Battery main switch

72
5 Model overview
5.2 Illustrations of arrangement

5.2.3 TGL Euro 6 tipper

AB AdBlue® tank

B Battery

H Hydraulic oil tank

K Fuel tank

N EMERGENCY-OFF switch

T Battery main switch

73
5 Model overview
5.2 Illustrations of arrangement

5.2.4 TGM Euro 6 chassis

AB AdBlue® tank

B Battery

H Hydraulic oil tank

K Fuel tank

N EMERGENCY-OFF switch

T Battery main switch

74
5 Model overview
5.2 Illustrations of arrangement

5.2.5 TGM Euro 3-5 tipper

B Battery

H Hydraulic oil tank

K Fuel tank

N EMERGENCY-OFF switch

T Battery main switch

75
5 Model overview
5.2 Illustrations of arrangement

5.2.6 TGM Euro 6 tipper

AB AdBlue® tank

B Battery

H Hydraulic oil tank

K Fuel tank

N EMERGENCY-OFF switch

T Battery main switch

76
5 Model overview
5.2 Illustrations of arrangement

5.2.7 TGS/TGX 2-axle chassis

AB AdBlue® tank

B Battery

H Hydraulic oil tank

K Fuel tank

N EMERGENCY-OFF switch

T Battery main switch

77
5 Model overview
5.2 Illustrations of arrangement

5.2.8 TGS/TGX 2-axle semi-trailer

AB AdBlue® tank

B Battery

H Hydraulic oil tank

K Fuel tank

N EMERGENCY-OFF switch

T Battery main switch

78
5 Model overview
5.2 Illustrations of arrangement

5.2.9 TGS/TGX 3-axle

AB AdBlue® tank

B Battery

H Hydraulic oil tank

K Fuel tank

N EMERGENCY-OFF switch

T Battery main switch

79
5 Model overview
5.2 Illustrations of arrangement

5.2.10 TGS/TGX 4-axle

AB AdBlue® tank

B Battery

H Hydraulic oil tank

K Fuel tank

N EMERGENCY-OFF switch

T Battery main switch

80
Notes

81
 81.99185-4294_RTL_15_04_TRUCK_ENG.pdf 1 04.05.2015 13:32:34

81.99185-4294
Text and Illustrations are not binding.
Changes, caused by technical process reserved.

CM

MY

CY

CMY

MAN Truck & Bus AG

Dachauer Strasse 667
80995 München
www.man.eu

Rescue Guide
Truck

MAN Truck & Bus - a company of the MAN group. MAN kann.