TGA / TGS – TRUCKS RSA & EXPORT

CHECKLIST FOR MAINTENANCE WORK

Customer: Registration no: Job no:

Vehicle type: Acceptance date:

Customer signature: Chassis no: Name of service advisor:

Current km:

Tick oil changes Enter oil Tick service Enter remaining life left of brakes/
that are due
 specification that is due
 clutch in %. Read out using MAN-
 Running in service cats II
Engine
E after 500 km to 
Gearbox  5000 km
clutch

Retarder  S6 Every 6 months 

Driven axles  S12 Every 12 months 
Transfer case  Maintenance 
Power steering  Winter service 
Tipper hydraulics 

Tick additional work that is due every time Tick additional work that is due After max
the oil is changed
 at each service interval Km Years

Engine: Fit a new engine oil filter insert  Fit a new air dryer desiccant
180 000 2 
Fit a new fuel filter insert Clean  Cartridge and silencer
the fuel pre-cleaner filter  Replace gearbox and axle breathers 240 000 2 
ZF 16 S gearbox with Intarder  Fit a new air filter insert Check

indicator 2
Fit a new filter insert Inner and outer
ZF ASTRONIC gearbox with intarder  Change coolant and fit a new a 
360,000 2
Fit a new filter insert radiator pressure cap
D20/D26 engines  
Replace radiator filler cap (green) 180 000 1
Replace oil separator filter element
Maintenance Group A+  1st steering inspection
360 000 2 
Engine: oil sample (wear check) at every service Power steering
Each subsequent 
180 000 1
steering inspection

Checklist pages 1 – 9: Tick work that has been completed ()

Maintenance system……...Operators manual Antifreeze checked…………………………………..%
Service products…………..Recommended Service Products Oil drain plugs tightened…………………………….
Fill volumes………………...Operators Manual Oil topped up, oil level checked……………………
Maintenance Manual Wheel nuts tightened………………………………..
Maintenance work…………Maintenance Manual Vehicle ready for operation…………………………
Confirmation……………….Maintenance Record
Filling the checklist………..File with job …………………………………
Job completed on (date)

Perform a brief test run and check the brakes after ………………………………………...
Completing work! Job completed by

SD340 MTB-RSA 2014 / revision 5 1

 TABLE OF ENGINE, AXLE AND GEARBOX OIL CHANGE INTERVALS (SYNTHETIC OIL)
GROUP A
ENGINE GROUP B GROUP C MAINTENANCE GROUPS FOR T G A/ TGS TRUCKS

ENGINE
In long haul transport

ENGINE
HOURS
AXLES

AXLES
KM KM KM A
G/BOX

AXLES
G/BOX

G/BOX
Covering over 80,000 km per year
X X X
In short haul transport
1000 1000 1000 B
Covering 10,000 km to >80,000 km per year
30 Χ 25 Χ 300 15 Χ In arduous conditions
60 Χ 50 Χ 600 30 Χ Or those covering up to 10,000 km per year
90 Χ 75 Χ 900 45 Χ e.g. all wheel drive tippers, vehicles with
120 Χ Χ 100 Χ X 1200 60 Χ machine attachments such as concrete
150 Χ 125 Χ 1500 75 Χ mixers or concrete pumps, refuse, fire
X C
180 Χ 150 Χ 1800 90 Χ fighting, recovery and towing vehicles, also
X vehicles whose engine operating
210 Χ 175 Χ 2100 105 Χ
240 Χ Χ Χ 200 Χ Χ 2400 120 Χ Χ temperature fluctuates, predominantly
X X around the minimum value and vehicles
270 Χ 225 Χ 2700 135 Χ used predominantly on gravel roads
300 Χ Χ Χ Time and kilometer dependant services complement
250 X 3000 150
each other. Please note that the kilometer dependant
330 Χ 275 Χ 3300 165 Χ
services are to be carried out in addition to and (not
360 Χ X 300 Χ X 3600 180 Χ X as an alternative to) the time dependant services.
390 Χ 325 Χ 3900 195 Χ You will find examples of how the two can be
420 Χ 350 Χ 4200 210 Χ combined in the Maintenance Record booklet.
450 Χ 375 Χ X 4500 225 Χ Before the onset of winter also carry out the winter
480 Χ Χ Χ 400 Χ Χ 4800 240 Χ Χ service, if possible together with a convenient S6 or
X X S12 service.
510 Χ 425 Χ 5100 255 Χ ENGINE OIL CHANGE INTERVALS
540 Χ 450 Χ 5400 270 Χ X M3277
570 Χ 475 Χ 5700 285 Χ A 30,000 km
600 Χ X 500 Χ X X 6000 300 Χ B 25, 000 km
630 Χ 525 Χ 6300 315 Χ 6 MONTHS at the latest or after 300
660 Χ 550 Χ 6600 330 Χ C
hours of operation or 15, 000 km
690 Χ 575 Χ 6900 345 Χ GEARBOX OIL CHANGE INTERVALS
720 Χ Χ Χ 600 Χ Χ 7200 360 Χ Χ Χ MAN 341 Typ Z5
X X A 240,000 km
750 Χ 625 Χ X 7500 375 Χ
B 125, 000 km
780 Χ 650 Χ 7800 390 Χ
2 YEARS at the latest or after 2 400 hours
810 Χ 675 Χ 8100 405 Χ C
of operation or 120, 000 km
840 Χ X 700 Χ X 8400 420 Χ
REAR AXLE OIL CHANGE INTERVALS
870 Χ 725 Χ 8700 435 Χ
900 Χ 750 Χ 9000 450 Χ MAN 342 Typ S1
X X
930 Χ 775 Χ 9300 465 Χ HYPOID AXLE
960 Χ Χ Χ 800 Χ Χ 9600 480 Χ Χ
240,000 km / 2 years
X X
990 Χ 825 Χ X 9900 495 Χ PLANETARY AXLE
1020 Χ 850 Χ 10200 510 Χ
MAN 342 TYP S1
1050 Χ 875 Χ 10500 525 Χ
1080 Χ X 900 Χ X 12000 540 Χ X
1 hour = 50 km
SERVICING – OIL CHANGE INTERVALS (SYNTHETIC OIL)
OIL CHANGE GROUP A  GROUP B  GROUP C 
Every 15,000 km
1 Change engine oil and filter Every 30,000 km  Every 25,000 km  or 300 hrs/6months

Every 240,000 km Every 200,000 km Every 120,000 km
2 MAN driven axles (Hypoid Axle)
or 2 years
 or 2 years
 or 2400 hrs/2 years

Every 120,000 km Every 100,000 km Every 90,000 km
2a MAN driven axles (Planetary Axle)
or 2 years
  or 2 years

or 2 years
or 2 years
Every 240,000 km Every 125,000 km Every 120,000 km
3 ZF AS-Tronic gearbox with / without Intarder
or 2 years
 or 2 years
 or 2400 hrs/2 years

Every 240,000 km Every 200,000 km Every 120,000 km
4 ZF Ecosplit gearbox with / without Intarder
or 2 years
 or 2 years
 or 2400 hrs/2 years

5 Change axle and gearbox breathers Every 240,000 km  Every 240,000km  Every 240,000 km 

SD340 MTB-RSA 2014 / revision 5 2

 ENGINE, GEARBOX AND AXLE OIL CHANGE INTERVALS (SYNTHETIC OIL)

TGS VEHICLES WITH D2066 AND D2676 EURO 2 ENGINES (NON EGR)
OPERATING IN MAINTENANCE GROUP A+ (Covering over150 000 km per year)

GROUP A+
KM ENGINE GEARBOX AXLE
40 000 Χ
80 000 Χ
120 000 Χ
160 000 Χ
200 000 Χ
240 000 Χ Χ Χ
280 000 Χ
320 000 Χ
360 000 Χ
400 000 Χ
440 000 Χ
480 000 Χ Χ Χ
520 000 Χ
560 000 Χ
600 000 Χ
640 000 Χ
680 000 Χ
720 000 Χ Χ Χ
760 000 Χ
800 000 Χ
840 000 Χ
880 000 Χ
920 000 Χ
960 000 Χ Χ Χ
1 000 000 Χ
1 040 000 Χ
1 080 000 Χ
1 120 000 Χ
1 160 000 Χ
1 200 000 Χ Χ Χ
1 240 000 Χ

MAINTENANCE GROUP A + FOR TGS TRUCKS

In long haul transport
Covering over 150,000 km per year.
Criteria to be met before Fuel consumption : 48l – 55l / 100km
authorizing any A+ service Fuel sulphur below <500 ppm
Oil as per M3277 Castrol Enduron 10w - 40
Oil sample (wear check) at every service
Before the onset of winter also carry out the winter service, if possible together with a convenient S6 or
S12 service.
ENGINE OIL CHANGE INTERVALS
M3277 Castrol Enduron 10w - 40
A+ 40,000 km
GEARBOX OIL CHANGE INTERVALS
MAN 341 Typ Z5 Castrol Syntrans MAX
A+ 240,000 km
REAR AXLE OIL CHANGE INTERVALS
MAN 342 Typ S1 Castrol Syntrax Longlife
HYPOID AXLE
A+ 240,000 km

PLEASE NOTE: THE FIRST FILLING OF ENGINE, GEARBOX AND HY AXLES ARE FACTORY FILLED WITH SYNTHETIC OIL
AND MUST NOT BE DRAINED ON THE E SERVICE

SD340 MTB-RSA 2014 / revision 5 3

 MAINTENANCE SERVICE TGA / TGS – TRUCKS
MAINTENANCE GROUP
A B C 
10 Air cleaner with dust extraction valve: remove dust Every engine oil change 
nd
11 Change air filter elements: 1 inner for every 2 Renew according to service interval indicator on display.
outer. Inspect clean air pipe from air cleaner to Renew both filters every two years irrespective of indicator 
engine status
12 Change fuel filter element. Clean the pre-
cleaner strainer filter
Every engine oil change 
13 Change Separ / Donaldson element including
sealing rings. Drain off water if necessary
Every engine oil change 
14 Renew radiator pressure cap Every second S12 service (every two years) 
15 Renew radiator filler cap (green) Every S12 service (once a year) 
16 Drain 10 litres antifreeze and top up with pre-mix
See T.B 2009/007 group 0 (Record on page1)
Every engine oil change 
17 Wheel nuts observe tightening torque Every engine oil change 
18 Tyres: Check pressures and correct if necessary
(including spare wheel) Check for external condition, Every engine oil change 
tread depth and tread pattern
19 Check for water in air tanks, drain if necessary Every engine oil change 
20 Pressure test cooling/heating system: check for
leaks, inspect core for clogging
Every engine oil change 
21 Grease trailer/fifth wheel coupling Every engine oil change 
22 Retorque cylinder head bolts:(for D28 4 valve
Minimum mileage 1000 km
engine with bolts tightened by angle)
Maximum mileage 30 000 km

Excluding all Common Rail engines
23 Check A-frame ball joints for wear Every engine oil change 
24 Check propshaft bolts, sliding joint free play and
Every engine oil change
condition of universal joints and grease as 
necessary
25 Check PTO and hydraulic pump for oil leaks if fitted Every engine oil change 
26 Change engine oil separator filter element(D20/D26) Every engine oil change 
GPOUP A GPOUP B GPOUP C
27 Remove injectors and send for servicing (replace
180,000km 150,000km 90,000km
nozzles) Excluding all Common Rail engines
or once a year
D
or once a year
D
or once a year

28 Remove injector pump and injectors and send 360,000km 300,000km 180,000km
for servicing Excluding all Common Rail engines or 2 years
D
or 2 years
D
or 2 years

Every Every Every service
29 Check and adjust valve clearance as necessary
service
D
service
D 
30 Check for wear and damage of poly-v belt Adjust if Every Every Every
necessary using special tool service D service D service 

CHECKING FLUID LEVELS – TOP UP IF NECESSARY

31 ZF Intarder and non Intarder gearboxes Every engine oil change and E service 
32 MAN driven axles including power divider Every engine oil change and E service 
33 MAN transfer case Every engine oil change and E service 
34 Engine oil (check at dipstick) Every engine oil change and E service 
35 Cab tilt mechanism Every engine oil change and E service 
36 Tipper hydraulics Every engine oil change and E service 
37 Hydraulic clutch and gear shift actuator (level in tank) Use only
Pentosin (M3289)
Every engine oil change and E service 
38 Battery electrolyte level: top up with distilled water
if necessary
Every engine oil change and E service 
39 Check power steering oil Every engine oil change and E service 
40 Top up windscreen washers and headlight cleaning system Every engine oil change and E service 
PLEASE NOTE: RETORQUE OF CYLINDER HEAD BOLTS ONLY ON D28 NON COMMON RAIL ENGINES
SD340 MTB-RSA 2014 / revision 5 4
 OPERATION – SPECIFIC MAINTENANCE WORK TGA / TGS – TRUCKS

SYSTEM DIAGNOSIS: E S6 S12

41 Read out fault memory (using MAN-cats II)   
42 Read out the remaining brake and clutch life (using MAN-cats II) Record % on page 1   
RENEW:
43 Air drier: If there is water in the air tank, drain it off and fit a new cartridge and silencer 
44 Air inlet, heating/ventilation/air-conditioning: Dust filter (Renew more often if dust build up is
heavy)
1

(1) Every second S12 service

LUBRICATION SERVICE
LUBRICATE USING AN OIL CAN OR GREASE
Linkages, cables, joints, bearings, hinges, catches
S6 S12
Check that the lubrication points connected to the central lubrication system are correctly supplied.
Lubricate those lubrication points not connected to the central lubrication system
45 Trailer/fifth wheel coupling  1
46 Spare wheel hoist cable  
47 Central lubrication system: Lubricant reservoir and lubricant supply  
48 Supporting structure for swop body: Main bearing journal thread, centring roller support  
49 Cab tilt mechanism: Locking mechanism  
50 Brake camshafts (planetary axle with drum brakes) 1 1
51 Slack adjusters (planetary axle with drum brakes) 1 1
52 Tipper body: Bearing points  
53 Oil change, ZF NMV power take-off with oil filter 
54 Oil change, tipper hydraulics 

(1) For vehicles without central lubrication system only

GENERAL TECHNICAL SAFETY

CHECK: Condition, correct functioning, effectiveness, leak-tightness, routing, damage, corrosion,
E S6 S12
chafing (Pay attention to routing / chaffing points) *
55 Engine, gearbox, PTO, hydraulic pump, retarder, driven axles, shock absorbers (visual
inspection)
  
56 Check steering system, including sealing bellows on ball joints   1
57 Check air suspension system for cracks, particularly rolling air bellows  
58 Trailer/fifth wheel coupling and fifth wheel plate  
59 Steering knuckles, also check end play 
CHECK: Firm seating, secureness
60 Wheel nuts (observe tightening torque)   
61 Spring U-bolts, spring mounting bolts (Retighten to specified torque)   
62 Steering, steering linkage, drop arm nut, steering mounting   
63 Spare wheel bracket and mounting   
64 Roof spoiler/aeropackage/supporting structure   
65 Tyres: Check pressures and correct if necessary (including spare wheel) Check for external
condition, tread depth and tread pattern

66 Check for water in air tanks, drain if necessary 

*If fluid loss is evident, determine cause and rectify

(1) Refer to ZF Inspection manual “LO” (every second S12 service)

SD340 MTB-RSA 2014 / revision 5 5

 SERVICING – CHECKING TGA / TGS – TRUCKS
CHECKING FLUID LEVELS – TOP UP IF NECESSARY S12
67 Air conditioning system: check refrigerant level and dryer, refill and fit new dryer if
necessary
1
68 Power take – off NMV 
69 Torque converter and clutch system (WSK), separate oil circuit 
(1) Must be checked by refrigerant expert

BRAKE TECHNICAL SAFETY

CHECK: Brake system, refer to service information number 54305 E S6 S12
70 Condition, leak-tightness, routing, damage, corrosion, chaffing, pad/lining and brake disc/brake
drum wear, functional check (including slack adjusters) and effectiveness test
  
71 Line filter: Remove and clean filter element 

PREVENTIVE INSPECTION
CHECK: Condition, correct functioning, effectiveness, leak-tightness, routing, damage, corrosion,
E S6 S12
chaffing (Pay attention to routing / chaffing points)
72 Cable connections, fastenings and routing: Battery, starter motor, alternator, earthing point   
73 Cooling and heating system, radiator insect screen ; also dirt in air-conditioning condensor and
fins in radiator and intercooler
  
74 Cab: Tilting and locking mechanism, hydraulic system   
75 Intake/exhaust system/exhaust gas recirculation system   
76 Fuel system, including auxiliary air and/or water heater   
77 Locking function, steering/starter lock  
78 Tipper system including PTO and hydraulic pump secureness  
79 Central lubrication pump setting  
80 Cab mounts, including air suspension  
81 Air-conditioning system: Equipment fixtures, refrigerant line ports  1
82 Leaf suspension: Check that intermediate rubber layer is fitted  
83 Remove strata panel assembly and clean 2 
CHECK: Firm seating, secureness
84 Nuts and bolts: Engine, gearbox, axles, chassis, body mounting   
85 Trailer/fifth wheel coupling and fifth wheel plate   
86 Retighten cooling system hose clamps (omitted in the case of spring clamps in the charged air
area)
  

(1) Must be checked by refrigerant expert

(2) If vehicle is used in dusty or off road conditions

SD340 MTB-RSA 2014 / revision 5 6

 EXTERNAL CHECK TGA / TGS – TRUCKS
CHECKING – ADJUSTING – CHANGING E S6 S12
87 Check windscreen wipers and washers (replace blades if necessary)   
88 Check all lighting and reflectors   
89 Check rear view mirrors   
90 Check fuel tank mounting straps for securness   
91 Retighten pressure flange collar nut for injector nozzle holder Excluding all Common Rail engines 

CHECKS AND MINOR MAINTENANCE JOBS

CHECK: Display on instruments E S6 S12
92 Engine oil level: Read off from display   
93 Remaining brake/clutch life: Read off percentage from display (Record % on page1) 1 1 1
94 Fault memory: Read off entries from display 1 1 1
(1) Omitted if data was read out using MAN cats II

WINTER SERVICE
95 Windscreen washers: Top up fluid 
96 Cooling and heating system: Check antifreeze and top up if necessary 
97 Check headlights and adjust if necessary 
98 Check correct functioning and condition of auxiliary air and /or water heater 
99 Batteries: check acid strength 
100 Lubricate door lock cylinders (spray 09.15014-0024) 

Maintenance work for reconditioned engine (E service only): maintenance work for the reconditioned engine is
integrated in the normal maintenance cycle of the vehicle after this maintenance work has been performed.

Work, maintenance points E

CHECK:Condition, correct functioning, effectiveness, leak-tightness, routing, damage, corrosion, chaffing

101 Engine 
102 Clutch 
103 Intake/exhaust system 
104 Cooling and heating system 
105 Fuel system 
106 Cable connections and fixtures: Battery, starter, alternator, earthing points 
107 Steering systems 
CHECK: Firm seating, secureness
108 Nuts and bolts: engine 
109 Retorque cooling system hose clamps (omitted in the case of spring clamps in the charged air area) 

CHECKING AND ADJUSTMENT WORK:

110 Retighten cylinder head bolts (for D28 engine with bolts tightened by angle)
Minimum mileage 1000km, maximum 30 000km. Excluding all Common Rail engines 1
111 Retighten pressure flange collar nut for nozzle holder. (for D28 4-valve engine)
Excluding all Common Rail engines 1
112 Check valve clearance and adjust if necessary 
CHANGE:
113 Engine oil, also change filter 
LUBRICATE USING AN OIL CAN OR GREASE: Linkage, cables, joints, bearings, hinges 
(1) Omitted in the case of Common Rail engine

SD340 MTB-RSA 2014 / revision 5 7

 Protocol for tyre tread depth Left Right
Axle 1 (front) mm mm
Axle 2 (rear) mm mm mm mm
Axle 3 (rear) mm mm mm mm

Protocol for brake test

Service Brake Hand brake
Brake force Brake force
Left Right Left Right
Axle 1 (front) daN daN
Axle 2 (rear) daN daN daN daN
Axle 3 (rear) daN daN daN daN

SD340 MTB-RSA 2014 / revision 5