Maintenance Recommendations and

Recommended Service Products

81.99589–5032 07 – 2004
 MAINTENANCE RECOMMENDATIONS AND RECOMMENDED SERVICE PRODUCTS — 07–2004

INTERNET–ADRESSES:

MAN: MAN service products (approved products) can be found on the Internet at:
Access via the MAN homepage
→ http:\\www.man-mn.com
→ Products & Solutions
→ E-Business
ZF: The current ZF lists of lubricants can be found on the Internet at: www.zf.com -
>Service ->Techn. Informationen ->Schmierstoffliste
Voith: The current Voith lists of lubricants for DIWA gearboxes and retarders can be
found on the Internet at: www.voithturbo.de/index_d.htm ->Straße -
>Automatgetriebe ->E-Service
Allison: www.allisontransmission.com

We reserve the right to make modifications in the course of further development

© 2004 MAN Nutzfahrzeuge Aktiengesellschaft

Reprinting, copying or translation, even of extracts, is not allowed without written approval from MAN Nutzfahrzeuge AG. All rights under the
copyright law are strictly reserved by MAN Nutzfahrzeuge AG.
Changes require the written approval of MAN Nutzfahrzeuge AG. The vehicle manufacturer shall not be liable for any damages attributable
to unauthorised changes made to this "Maintenance Recommendations and Recommended Service Products" booklet.

VNSWD/Lü.: 07–2004 –Abruf Übersetzung + Satz: emes GmbH Druck: Druckerei Gebr. Bremberger, München (de–nl)
81.99589–5032 — englisch Friedrichshafen MAN-Werksdruckerei; DocuTech (pt +>>)
Maintenance Recommendations and
Recommended Service Products

Commercial vehicles, OEM components

and rail vehicles (see page 13 and 24)

Maintenance Systems
Service Products
Major Component Fill Quantities

81.99589–5032 07 – 2004
 INTRODUCTION

The present booklet is an updated version of the "Maintenance "ProFit-Check and ProFit-Check II" time-based maintenance
Recommendations and Recommended Service Products" booklet system
from 09–2003.
ProFit-Check II can be used for all L/M/F2000 and LE/ME/FE
The "Maintenance Recommendations and Recommended Service trucks. The "ProFit-Check" time-based maintenance system shall
Products" booklet is updated every 18 months or so and then continue to be applicable for newer-design buses and coaches
published as a new edition. The release of the new, updated from 09–2000 initially.
booklet renders the previous edition invalid in the case of all new The time-based maintenance system is based on your vehicle's
deliveries. annual mileage, planned by you in advance.
More precise details can be found on page 9 in the relevant
In this booklet, you will find the currently applicable Maintenance Record.
maintenance systems, depending on series and application,
for all .... "ProFit-Check II" maintenance system for the "TGA" series
The "ProFit-Check II" maintenance system applicable to vehicles
− MAN commercial vehicles in the "TGA" series is programmed into the maintenance
− OEM components for road vehicles computer, either as a "time-based maintenance system" or as a
− Rail vehicles (rail cars; see page 13 and 24) "flexible maintenance system".
More precise details can be found on pages 11 to 12, in the
delivered from 07–2004 onwards. relevant Maintenance Record and in the Maintenance Manual
WA 74 (Section 9.00 General, 9.01 Baseline, 9.02 Highline).
In the case of vehicles and major components delivered before Maintenance system based on maintenance groups
this date, the maintenance system in force at the time of delivery
applies, as specified in the "Maintenance Recommendations and Conscientiously select the maintenance group which best suits
Recommended Service Products" booklet supplied with the your vehicle's predominant application conditions (see
vehicle or major component. page 13) and mark this in the Maintenance Record booklet. In
case of doubt, select the shorter interval or ask a MAN Service
workshop. The staff there will be only too happy to offer you advice
However, the service products, specifications etc. are also valid and help.
and applicable in the case of vehicles and units supplied before If the predominant application conditions change, change the
the above date. maintenance group to suit these new conditions.

MAN Nutzfahrzeuge Gruppe

Aktiengesellschaft

3
INTRODUCTION

Most of the specified maintenance intervals are based on Central

European tests, trials and experience; this means they may not
necessarily apply to other countries.

In the case of vehicles which are operated under extreme

application conditions, e.g.
− prolonged extremely low or high outside temperatures,
− extremely high atmospheric humidity,
− frequent driving on poor surfaces (unconsolidated, dusty roads)
− frequent fording, especially in salt water, etc.

and/or if service products that do not fulfil MAN requirements in

every respect are used, shorter maintenance intervals must be
selected in order to prolong the life expectancy of your vehicle.
Please talk to MAN Service or your importer who will be only too
glad to help in any way. So that your MAN vehicle gives you
"happy motoring" for a long time to come.

This brochure is divided into the following main sections:

− Maintenance systems
− Service products
− Major component fill quantities.

For more precise details, please refer to the table of contents on

pages 5 – 7 as well as the index on pages 73 – 78.

4
 TABLE OF CONTENTS

Page Page
"ProFit-Check II" TIME-BASED MAINTENANCE SYSTEM L2000, Diesel engines with catalytic converter with particulate
matter filter (Euro 4) ..................................................................27
M2000, F2000, LE–C/B, ME–B, FE–A, and buses / coaches
System description ........................................................................... 9 Sulphur content in diesel fuel....................................................27
Viscosity regulations .................................................................27
"ProFit-Check" MAINTENANCE SYSTEM, TGA
Exceptions ................................................................................27
System description ................................................................. 11 – 12
Engine oils for CNG and LPG engines............................................28
MAINTENANCE SYSTEM BASED ON MAINTENANCE GROUPS Engine oil change intervals .......................................................28
Maintenance groups – allocation .................................................... 13 Diesel fuel........................................................................................29
Explanation of maintenance types .................................................. 14 Diesel fuel – low-sulphur / sulphur-free.....................................29
Maintenance interval – maintenance group A+ .............................. 15 Winter operation........................................................................29
Maintenance interval – maintenance group A ........................ 16 – 17 Fuel recommendations for winter operation..............................29
Maintenance interval – maintenance group B ........................ 18 – 19 Dangerous materials classes....................................................30
Maintenance interval – maintenance group C ........................ 20 – 21 Diesel fuel additives ..................................................................30
Engine oil change intervals for trucks (table).................................. 23 Biodiesel (FAME); e.g. rape seed oil methylester (RME)................30
Engine oil change intervals for buses / coaches, bus / coach Micro-organisms in the fuel system.................................................31
chassis FOC / HOC and rail vehicles (table) .................................. 24
CNG (compressed natural gas) used as fuel ..........................32 – 33
SERVICE PRODUCTS LPG (liquefied petroleum gas) used as fuel ....................................33
Approval of service products .......................................................... 25 Aviation turbine fuel (kerosene).......................................................34
Sample letter of approval................................................................ 25 Coolant ............................................................................................35
Engine oils for diesel engines – Euro 0, 1, 2, 3 .............................. 26 Antifreeze..................................................................................35
Super-high-performance diesel engine oils.............................. 26 Mixing table...............................................................................35
Single-grade engine oils........................................................... 26 Anti-corrosion agent..................................................................35
Engine oil additives .................................................................. 26 Antifreeze for Pritarder (water retarder) ....................................36
Miscibility of engine oils ............................................................ 26 Changing the coolant ................................................................36
Diesel engines with particulate trap (CRT system) .................. 27 Disposal ....................................................................................36

5
 TABLE OF CONTENTS

Page Page
Water quality ...................................................................................36 Torque converter and clutch system (WSK)............................. 43
Gear oils..........................................................................................37 Cable winch gearbox................................................................ 44
Gear oil change intervals ..........................................................37 Transfer case ................................................................... 44 – 45
Viscosity regulations .................................................................37 Steering gear............................................................................ 45
Gear oils to Works Standard Steering gear / trailing axle steering, TGA ............................... 45
MAN 341, 342 and M 3343............................................37 – 38
Retarder.......................................................................................... 46
Automatic transmission fluids (ATF) ...............................................38
Axles ....................................................................................... 47 – 48
Hydraulic fluids to M 3289 ZHF.......................................................38
Driven axles.............................................................................. 47
Cleaning the outside of vehicles and major components................38
Driven trailing axles .................................................................. 47
Specifications
Non-driven axles ...................................................................... 48
Diesel engine ..................................................................................39
Wheel hub: Grease or oil fill ..................................................... 48
Lubrication ................................................................................39
Spring bearings ........................................................................ 48
Cooling......................................................................................39
Steering knuckle bearings: TGA grease fill .............................. 48
Fuel...........................................................................................39
Grease fill: Hub Unit ................................................................. 48
Gas engine (CNG / LPG) ................................................................40
Hydraulic systems................................................................... 49 – 51
Lubrication ................................................................................40 ®
Leading, trailing and rear axle steering (ZF–RAS or HS) ....... 49
Cooling......................................................................................40
Leading and trailing axle steering / steering gear TGA ............ 49
Fuel...........................................................................................40
Cab tilt hydraulics ..................................................................... 49
Gearbox Implement hydraulics (SX90/SX2000) ..................................... 50
Manual gearbox ................................................................40 – 41 Central hydraulic system (LX90/SX2000)................................. 50
ZF Duo Drive HZA (hydrostat) ..................................................41 Central hydraulic system in heavy-duty tractors
Automated manual gearbox (TipMatic – AS–Tronic)................42 (E, H, and T models) ................................................................ 50
Automated manual gearbox (TC–Tronic) .................................42 Brake and clutch actuator......................................................... 50
Automatic gearbox............................................................42 – 44 Clutch actuator and Kongsberg gear change system, TGA ..... 50

6
 TABLE OF CONTENTS

Page Page
Anti-jackknife system................................................................ 51 ZF New Ecosplit ..............................................................................63
Tipper hydraulics ...................................................................... 51 Torque converter and clutch system (WSK)....................................64
Refuse vehicle hydraulics......................................................... 51 ZF–Transmatic ................................................................................64
Central hydraulic system: Crane / winch .................................. 51 Eaton synchromesh gearbox...........................................................64
Lifting axle, hydraulic ................................................................ 51 Eaton Twin Splitter ..........................................................................65
Suspension, hydraulic .............................................................. 51 Automatic gearbox ..........................................................................65
Retarder ..........................................................................................65
Greasing points....................................................................... 52 – 54
Power take-offs ...............................................................................65
Periodic lubrication ........................................................... 52 – 53
Transfer case ..................................................................................66
Lifetime lubrication ........................................................... 53 – 54
Hydrostatic fan drive........................................................................66
Anti-corrosion protection................................................................. 55
Air-conditioning system / auxiliary air-conditioning unit (TGA) ........67
Batteries.......................................................................................... 55 Anti-jackknife system (SG / NG buses / coaches) ..........................67
Lifting axle, hydraulic .......................................................................67
Miscellaneous ......................................................................... 55 – 58
Trailing axle: hydraulic steering .......................................................67
Central lubrication system ................................................ 55 – 56
Leading axle, hydraulically steering.................................................67
Windscreen washers ................................................................ 57
Front axles.......................................................................................68
Tyres and rims.......................................................................... 57
Trailing axles, steering ....................................................................69
Hydrop shock absorber mount (Roland BAF) .......................... 57
Centre axles ....................................................................................69
Electrical compressor ............................................................... 57
Spring bearings ...............................................................................69
Auxiliary air-conditioning unit (TGA) ............................................... 57 Rear axles ...............................................................................70 – 72
Rear axles / hypoid axles ................................................................72
Air-conditioning systems................................................................. 58

INDEX .....................................................................................73 – 78
MAJOR COMPONENT FILL QUANTITIES
Engine..................................................................................... 59 – 61
NOTES ....................................................................................79 – 81
Manual gearbox .............................................................................. 63

7
 "PROFIT–CHECK II" TIME-BASED MAINTENANCE SYSTEM — TRUCKS (not incl. TG–A)

SYSTEM DESCRIPTION The services

First service, service with engine oil change, S12 service
Applicability Maintenance work is only performed during the first service and, for
The "ProFit-Check II" time-based maintenance system is standard every year of operation, during the service with engine oil change
for all LE/ME/FE (L/M/F2000) vehicles (not to X/HX models and and the S12 service.
heavy-duty tractors). The annual S12 services after 12 months should be scheduled to
The current "ProFit-Check" time-based maintenance system shall coincide with the statutory inspections. The S12 service is required
continue to be applicable for buses and coaches from 09–2000 irrespective of the oil change intervals.
initially.
Additional jobs
Trucks and buses / coaches already in service may be included if Additional jobs may include statutory inspections, winter servicing or
requested by the customer, subject to certain conditions; see the servicing of special equipment.
Maintenance Booklet "ProFit-Check II" or "ProFit-Check" for buses
and coaches. Oil changes
The oil (gearbox, axles etc.) is changed during the service with
The most important changes engine oil change and the S12 service, depending on when the oil
All vehicles are now only serviced during the service with engine oil change is due. The due date can be determined from the
change (depending on mileage) or the S12 service Acceptance Sheet.
(every 12 months). Selecting the optimal lubricant for the planned mileage over the next
The first service oil changes are omitted, with the exception of the year ensures that the next service with engine oil change or S12
ZF-WSK (torque converter and clutch system) and the service is reached.
ZF-Transmatic. The oil filter and the fuel filter are always renewed when the
The first service after 1000 – 5000 km now only involves checking engine oil is changed.
condition, correct functioning and firm seating.
The two engine oil change and S12 services include the
The customer defines the planned mileage for the next year each following work:
time the vehicle comes in for a service. These details are used to
determine the optimal lubricant for reaching the next service. Maintenance depending on operating time
Checks for typical wear caused by operation.
The oil (gearbox, axles etc.) is changed during the service with
engine oil change or the S12 service, depending on when the oil The long-term maintenance includes work that is due after a
change is due. certain number of kilometres or after 2 or 4 years.
The calculated due dates are entered in the Maintenance Record in
order to provide a maintenance schedule for the customer and for Warranty claims will only be accepted if all work has been
the workshop. performed in full by a MAN Service workshop.
Having the intervals, lubricants and performance features on the
same acceptance form makes it much easier to select the optimal For further information, refer to the "ProFit-Check II" Maintenance
lubricants. Record.
9
 "PROFIT–CHECK II" MAINTENANCE SYSTEM — TGA

SYSTEM DESCRIPTION before the next oil change is required. Selecting a service product of
higher quality or the highest quality guarantees you the longest
Applicability possible oil change intervals, assuming the vehicle is driven
The "ProFit-Check II" maintenance system can also be used for sensibly.
TGA series vehicles (not for HX and heavy-duty tractors); however,
it contains a choice of 2 versions that can be programmed into the By way of example, the oil change interval for engine oil to Works
maintenance computer. Standard M 3277 is almost double that of engine oil to MAN 271.

Time-based maintenance system Depending on application conditions and service product, the
• The MAN workshop dates for oil changes and other maintenance maximum intervals are currently as follows, e.g.:
work coincide so as to reduce the number of visits to the Euro 3 –D20../D28.. CR engines * ...................................120,000 km
workshop. Euro 3 –D08.. CR engines * ...............................................60,000 km
• New vehicles are already pre-programmed with the time-based Euro 2/3 –D28 engines * ..................................................100,000 km
maintenance system. Manual gearbox without special breather* .......................360,000 km
Manual gearbox with special breather* ............................500,000 km
Flexible maintenance system Driven HY axles without special breather* .......................360,000 km
• The flexible maintenance system allows you to operate each Driven HY axle (HY–1350) with special breather* ................500,000 km
major component until it reaches its maximum permitted mileage. *) engines after 1 year at the latest, gearbox and axles after 3 years at the latest.
• In contrast to the time-based maintenance system, this system (for details of further components, changing breathers etc. – see Acceptance Sheet and
Oil Change Sheet TGA).
displays the remaining permitted mileage separately for each
major component. Be sure to make the right choice!
Only MAN Service workshops are able to change the setting from This will bring you major cost savings. And you will be doing your bit
time-based maintenance system to flexible maintenance system. for the environment as there will be less used oil requiring disposal.
What's more, your MAN vehicle will thank you by giving you
A description of the maintenance system can be found in the constant availability and a long service life.
Maintenance Record booklet and in Maintenance Manual WA 74.
Due oil changes (axles, gearbox etc.) as well as the services with MAINTENANCE INDICATORS
engine oil change (indication on display: Service due) and S12 Displays
services (indication on display: S12 service due, possible from Switch on the ignition and select one of the following menu items or
vehicle management computer step 6.5) which are to be carried out other information:
after each year of operation are determined by the maintenance
computer and indicated on the display in the vehicle.
Maintenance
Statutory tests and inspections can also be displayed.
First registration
Once you have selected the service product and entered the The first registration date must be entered using MAN-cats the first
information in the maintenance computer (see Maintenance Manual time the vehicle comes into the workshop. Only your MAN Service
WA 74), the computer work outs the distance which can be driven workshop is able to do this.

11
 "PROFIT–CHECK II" MAINTENANCE SYSTEM — TGA

• The maintenance menu also contains the following items: The two engine oil change and S12 services include the
following work:
Dates
Display of dates on which maintenance is due. Confirmation of Operation-specific work
the maintenance work performed (only possible using MAN-cats). Checks for typical wear caused by operation.
Approved oil specifications.
The long-term maintenance includes work that is due after a
Qualities
certain number of kilometres or after 2 or 4 years.
Current oils used in the engine, gearbox, transfer case and axle.
Parameters Warranty claims will only be accepted if all maintenance work has
Display indicating whether time-based or flexible maintenance been performed by MAN Service.
system has been programmed.
Option for defining when the due date is displayed, i.e. number of For further information, refer to the "Trucknology Generation A
weeks or km in advance of the due date (only possible using (TGA)" Maintenance Record.
MAN-cats).

In the interests of vehicle operational reliability and road safety, it is

absolutely imperative that you comply with the displayed
maintenance dates and statutory test / inspection dates.

We would also ask you to regularly check the vehicle yourself and
recommend that you carry out the inspection work and care
procedures specified in the Operator's Manual supplied with your
vehicle.

The services include the following work:

"ProFit-Check II" specifies oil changes (gearbox, axles etc.) as well
as the service with engine oil change (depending on mileage) and
S12 service (every 12 months) due after each year of operation and
the long-term maintenance.

12
 MAINTENANCE SYSTEM BASED ON MAINTENANCE GROUPS

ALLOCATION INTO MAINTENANCE GROUPS

The following 4 application-specific maintenance groups take into maintenance group with the shorter intervals or ask a MAN Service
account the various operating conditions which affect maintenance workshop.
type and maintenance interval.
If it is not clear which maintenance group is right for your vehicle Mark the relevant Maintenance Group in the Maintenance Record.
and its application conditions, we recommend you select the

Maintenance Forward-control vehicles, heavy range – F2000 (FE–A) long-haul and touring coaches,
group
covering more than 150,000 km per year
A+ Conditions: With central lubrication system as well as the major components and service products listed on page 15!

Long-haul trucks (L2000, M2000, F2000, LE–C/B, ME–B, FE–A)

Maintenance covering more than 80,000 km per year.
group
Coaches, regardless of annual mileage and rail vehicles *)
A covering more than 80,000 km per year.
Coach chassis FOC/HOC, regardless of annual mileage.

Short-haul trucks (L2000, M2000, F2000, LE–C/B, ME–B, FE–A, FX 2000),

Maintenance covering 10,000 to 80,000 km per year, predominantly used in urban areas.
group
Buses, regardless of annual mileage.
B
Bus chassis FOC/HOC, regardless of annual mileage.

Heavy-purpose vehicles or vehicles covering less than 10,000 km per year

Maintenance
group e.g. rough terrain vehicles (X models), all-wheel drive tippers, vehicles with implements such as concrete / cement
mixers or pumps etc., refuse trucks, water tenders, rescue and recovery vehicles, off-road machinery; heavy-
C tonnage transporters (F2000/TGA), vehicles in which the engine runs at idling speed for long periods, vehicles
in which the engine operating temperature predominantly remains at minimum levels and vehicles
predominantly used on unconsolidated road surfaces.

*) limited to rail cars (no locomotives) with application profile typical of a bus. Exceptions are subject to separate agreement with MAN.

13
 MAINTENANCE SYSTEM BASED ON MAINTENANCE GROUPS

MAINTENANCE TYPES
(key to the following maintenance interval surveys)

E = Running-in service
due after 1000 to 5000 km
However, if the 6 months are reached beforehand in maintenance group "C", the running-in service is due after 6 months.

F = Mileage-dependent maintenance work

which is due after a certain number of kilometres or operating hours, depending on the maintenance group, and which must
be performed in addition to maintenance type Z.
Type: F 1 = Interim lubrication service (only required if no central lubrication system is installed. In the case of difficult
application conditions, we recommend lubricating the propshafts in between).
F 2 and F 3 = Services

Z = Time-dependent maintenance work

to be performed in addition to maintenance type F, regardless of mileage.
Type: Z 1 = Additional work (every 6 months)
Z 2 = Additional work (every 12 months)

Important!
Please refer to relevant MAN maintenance lists, MAN maintenance manuals or manufacturer's documentation for maintenance intervals
not specified in this booklet, e.g. for steering system, steering knuckle bearings, wheel bearings, major components from other suppliers
etc.

14
 MAINTENANCE INTERVALS – MAINTENANCE GROUP A+

A+
Major component oil or fluid changes
Voith
D 28 .. engines Manual gearbox Hypoid axles
(Euro 0, 1, 2, 3) Retarder
1)
ZF Eaton R 115
M3277
Service product to (see page 23 / 24) MAN MAN MAN MAN MAN 342 MAN 342 M 3277, M 3275
MAN Works Standard 341 SL, 341 ML, 341 SL, 341 ML, SL ML, synthetic /
TL M 3343 TL M 3343 M 3343 semi-synthetic
ML, SL ML, SL ML, SL
Maintenance Maintenance For service products / specifications, see page ...
type intervals Dipstick ring
Green £ Red ¤ 40 40 40 40 47 47 46
(due after)
(with engine oil filter and
fuel filter change)

E km 1000 – 5000 — — — — — — — — — X

60,000 km — ¤ — — — — — — — —
Every
F2 80,000 km
£ — — — — — — — — X
Every
F3 160,000 km
— — — X — X — X
3)
X X

Every 2nd Every 2) 2) 2)

— — X — X — X — — —
F3 320,000 km
Every — — — — — — — — — X
Z1 6 months
Every — — — — — — — — — X
Z2 12 months
1)
With ZF secondary retarder or ZF-Intarder: only MAN 341 type SL or TL approved.
2) 3)
Max. 360,000 km permitted with gear oil type SL Max. 180,000 km permitted with gear oil type M 3343 SL
£ Green dipstick ring or 10-litre auxiliary tank in buses and coaches or MAN bypass oil filter

15
 MAINTENANCE INTERVALS – MAINTENANCE GROUP A MAINTENANCE INTERVALS – MAINTENANCE GROUP A

A
Major component oil or fluid changes Major component oil or fluid changes
Hydrostatic Voith Automatic gearbox
D 28 .. D 08 .. Manual gearbox ZF AS–Tronic ZF Trans- WSK Hypoid axles and driven bus / Planetary axles
fan drive 2) Retar- (with / without retarder)
engines engines Eaton / ZF (MAN-Tipmatic) matic coach axles and HN9–90L Mainten-
der ZF Ecomat (HP)
Service product to M M MAN M M MAN + filter MAN 341 MAN 341 M 3343 Only ZF 2) MAN 341 / M 3343 all M 3275 ATF MAN 339, ATF MAN 339, MAN 270 MAN MAN MAN 342 SL MAN 342 N, M 3343 ML, MAN 342 N, ML M 3343 SL, ance
3277 3275 271 3277 3275 271 SL, TL N, ML ML, SL also models (with Intarder, M 3277 type D+F synth. type D+F SAE 30 339, 270 SL M 3343 ML MAN 342 SL
MAN Works Standard
change
MAN 270 work as
only MAN 341 TL, SL) D+F SAE 30 MAN 342 ML
Same engine
per
Maintenance Maintenance Dipstick ring For service products / specifications, see page ... For service products / specifications, see page ...
oil as engine checklist
type intervals Green £ Red ¤
(due after) (with engine oil filter and 39 40 40 40 40 42 46 43 43 43 43 47 47 47 47 47
fuel filter change)

E km 1000 – 5000 — — — — — — — — — — — — — — — X X — — — — — X

F1* Every 15,000 km — — — — — — — — — — — — — — — — — — — — — — X

Every 20,000 km — — — — — ¤ — — — — — — — — — — — — — — — — —
Every 30,000 km — — ¤ — ¤ — — — — — — — — — — — — — — — — — —
1)
Every 35,000 km — — — — — £ — — — — — — — — X — — — — — — — —
—
F2 Every 45,000 km — ¤ £ ¤ £ — — — — — — — — — — — — — — — — X
Every 60,000 km —
¤ £ — £ — — — — — — — — — — — — — — — — —
Every 80,000 km 1)
£ — — — — — — — — — — — — — — X — — — — — — —
—
F3 Every 90,000 km — — — — — — — X X X X X
6)
X
3)
— — X
1)
— X — X — X
2nd F 3 Every X 9)SL 8) 8) 9)
180,000 km — — — — — — — X — =160.000 — — — — — — — X — X — X —
Every 320,000 km 4), 8) 4), 8)
— — — — — — — X — — — — — — — — — X — — — — —
4th F 3 Every 360,000 km — — — — — — — X
5), 8)
— — — X
SL+, 8), 9)
— — — — — X
7), 8)
— — — — —
— — — — — — — — — — — — — — — — — — — — — — X
Z1 Every 6 months
— — — — — — X — — — — — — — — — — — — — — — X
Z2 Every 12 months
*) Omitted if central lubrication system fitted 1) After 1 year at the latest 3) With synthetic ATF MAN 339 type D/F (approved products only) every 120,000 km, after 2 years at the latest
2) ZF secondary retarder / Intarder only MAN 341, type SL / TL or MAN 270, SAE 30 6) 160,000 km permitted with synth. / semi-synth. engine oil (every 0W–X, 5W–X, 10W–X)
4) For M/L2000, LE–C/B, ME–B and oil grade SL 5) For F2000, FE–A and oil grade SL 7) F2000, FE–A and coaches 8) After 3 years at the latest 9) After 2 years at the latest
£ Green dipstick ring or 10-litre auxiliary tank in buses and coaches or MAN bypass oil filter
16 17
MAINTENANCE INTERVALS – MAINTENANCE GROUP B MAINTENANCE INTERVALS – MAINTENANCE GROUP B

B
Major component oil or fluid changes Major component oil or fluid changes
Hydro- ZF AS- ZF Voith Automatic gearbox WSK
D 28 .. D 08 .. E/G static Manual gearbox (with / without retarder) Hypoid axles and driven Planetary axles Transfer case
6) Tronic Trans- Re- Torque
engines engines 08../ 28.. fan Eaton / ZF converter and bus / coach axles and HN9–90L Mainten-
(Tipmatic) matic tarder Allison Voith Diwa,
T = Truck, B = Bus T = Truck, B = Bus engines drive ZF Ecomat AT/MT/HT Midimat clutch system ance
+ filter Only MAN 341 / MAN MAN ATF MAN 339, MAN 270 MAN 342
Service product to M 3343 (with
work as
M M MAN M M MAN M 3271 –1 change MAN MAN M 3343 ZF also MAN M 3275 339, 339, ATF MAN 339, type D+F SAE 30, ATF MAN 342 MAN 342 M 3343 MAN 342 N, ML, MAN 342 SL MAN 342 N, ML
MAN Works Standard 3277 3275 271 3277 3275 271 Gas Same oil 341 341 ML, SL MAN
Intarder, only
MAN 341 TL, 270 SAE M 3277 D+F D+F type D+F MAN 339, type SL N, ML ML, SL M 3343 ML M 3343 SL SL M 3343 per
as engine SL, TL N, ML 6) 30 synth. mineral synth. D+F ML, SL
270 SL) checklist
Maintenance Maintenance Dipstick ring For specifications / approved products, see pages ... For specifications / approved products, see pages ... xx/xx
type intervals Green £ Red ¤ 40 39 40 40 40 40 42 43 46 43 38 44 43 43 47 47 47 47 47 45 45
(due after) (with engine oil filter and
fuel filter change)

E km 1000 – 5000 — — — — — — ¤ — — — — — — X — — — — Diwa — X — — — — — — — X

Midimat X

F1* Every 15,000 km — —- — — — — — — — — — — — — — — — — — — — — — — — — — X

Every 20,000 km — ¤T — — ¤T — — — — — — — — — — — — — — — — — — — — — —
F2 Every 30,000 km — ¤ £T ¤T ¤ £T ¤ — — — — — — — — — X
2)
— Midimat X
2)
— — — — — — — — X
T+B ¤B T+B ¤B
Every 40,000 km 4)
— £T — — £T — — — — — — — — — — — — X — — — — — — — — — —
Every 45,000 km ¤ £T
— — — — — — — — — — — — — — — — — — — — — — — — — —
T+B ¤B
Diwa 2) 3), 9)
£ X
F3 Every 60,000 km
T+B
£B — £B £B — — — — X
3)
X
3)
X
3)
X
2)
X
7)
— — X
3) — X
2)
— X
3)
X
3)
X
3)
—
VG 750
X VG 750
2) X
5) 3) Diwa X
3)
—
2nd F 3 Every 120,000 km — — — — — — — — X — — — X — — X — — — — X
3)
X
3), 8) — —
— X5) HONP1),3) HONP1),3)
— — — — — — — — — — — — — — — — — — — — — — — — — — — X
Z1 Every 6 months
— — — — — — — X — — — — — — — — — — — — — — — — — — — X
Z2 Every 12 months
*) Omitted if central lubrication system fitted 1) HONP with SL = 240,000 km; with ML = 120,000 km 2) After 1 year at the latest 4) AT with paper filter every 40,000 km, with brass filter every 80,000 km, MT every 40,000 km, HT every 80,000 km. All after 1 year at the latest.
6) ZF secondary retarder / Intarder only MAN 341, type SL / TL or MAN 270, SAE 30. 3) After 2 years at the latest 5) After 3 years at the latest 7) 90,000 km permitted with synth. / semi-synth. engine oil (every 0W–X, 5W–X, 10W–X)
£ Green dipstick ring or 10-litre auxiliary tank in buses and coaches or MAN bypass oil filter 8) For transfer case G102/103/172/173/252/253: only MAN 342 SL approved 9) VG 1600 (SAE 85W–90) + 2)

18 19
 MAINTENANCE INTERVALS – MAINTENANCE GROUP C MAINTENANCE INTERVALS – MAINTENANCE GROUP C

C
Major component oil or fluid changes Major component oil or fluid changes
Hydro- Automatic gearbox (with / without retarder
D 08 .. / D 28 .. E/G static Manual gearbox ZF ZF Voith WSK WSK Hypoid axles Planetary axles Transfer case
7) Voith Allison Allison Renk Torque
engines 08../ 28.. fan Eaton / ZF TC– Trans- Re- 440 and driven bus / and HN9–90L Mainten-
Diwa, ZF Ecomat AT/MT CLT, Remat converter and
engines drive Tronic matic tarder (TC2)
Midimat / HT CLBT, WT clutch system coach axles ance
+ filter MAN 341 MAN MAN ATF MAN MAN 270 / MAN 270 MAN 270 MAN 270 MAN 342 MAN 342 work
Service product to M3277, M3275 M3271–1 change MAN 341 N, ML, MAN 341 MAN 270 M 3275 ATF MAN 339, 339, 339, type 271, 10W SAE 30, SAE 30 MAN 342 N, ML, MAN 342 N, ML, M3343 ML, SL MAN 342 N, ML,
MAN 271 Gas Same oil SL, TL M 3343 SL+ SAE 30 M 3277 339, type D+F D+F D+F SAE 30 ATF MAN 339, SL M3343 SL SL M3343
as per
MAN Works Standard
as engine ML, SL D+F synth. /15W–40 type D+F ML, SL ML checklist
Maintenance Maintenance intervals Dipstick ring 34 / /51
For service products specifications, see page .. For service products / specifications, see page ... xx/xx
type (due after) Green £ Red ¤ 39 40 40 42 43 46 43 43 43 44 44 44 43 43 47 47 47 47 45 45
(with engine oil filter and
fuel filter change)

E km 1000 – 5000 — ¤ — — — — X — Diwa – — — — — X X X — — — — — — X

(after 6 months at the latest) Midimat X
5)
F1* Every 6 months, every 200 hours or — — — — — — — — — — — — — X — — — — — — — — X
10,000 km at the latest
Midimat 5)
F2 Every 12 months, every 400 hours or ¤ ¤ — X
6)
X
6)
— X — X
2) — X X — X X X — — — — VG 750 X X
20,000 km at the latest X VG 750
Every 2) 2) 9), 2)
600 hours or 30,000 km £ — — — — — — — — — — — — — — — — — — — — X —
Diwa
F3 Every 24 months, every 800 hours or — — — — X
6)
— — X X
3)
ATF
— — — X X
5)
— — — X X X — X X
40,000 km at the latest mineral
Every 2nd Every 1600 hours or 80,000 km, 6, 4) 6, 4) Diwa 4) 4), 8)
— — — X — X — — X
4) X — — — — — — X — — — X — —
F3 every 36 months at the latest ATF
synthetic
— — — — — — — — — — — — — — — — — — — — — — X
Z1 Every 6 months
— — X — — — — — — — — — — — — — — — — — — — X
Z2 Every 12 months
*) Omitted if central lubrication system fitted, with the exception of oil change in Renk Remat gearbox if applicable, see 5) 5) Every 10,000 km or 500 operating hours, after 2 years at the latest.
1) After 1000 operating hours at the latest 2) After 1 year at the latest 6) Due during "F 2" if vehicle is frequently used off-road or if gearbox at operating temperature is regularly splashed by water; otherwise,
3) After 2 years at the latest 4) After 3 years at the latest during "F 3". 8) For transfer case G102/103/172/173/252/253: only MAN 342 SL approved
hours = operating hours 7) ZF secondary retarder / Intarder only MAN 341, type SL / TL or MAN 270, SAE 30
£ Green dipstick ring or 10-litre auxiliary tank in buses and coaches or MAN bypass oil filter 9) VG 1600 + HP902 SAE 85W90

20 21
 ENGINE OIL CHANGE INTERVALS BASED ON MAINTENANCE GROUP

ENGINE OIL CHANGE INTERVALS FOR TRUCKS

The engine oil change intervals indicated (pages 15 to 21) – summarised again in the following table for reasons of clarity – only apply to
approved engine oils. Irrespective of the intervals indicated, the engine oil, oil filter and fuel filter must be changed at least once a year.
Multigrade
engine oils Maintenance group
to Works Standard .... A+ A+ A A B B C C
Diesel engine oils
Dipstick ring Green Red Green Red Green Red Green Red
MAN 271
D 08 engines —— —— 35,000 km 20,000 km 30,000 km 20,000 km 12 months, 12 months,
D 28 engines —— —— 45,000 km 30,000 km 30,000 km 20,000 km at the latest at the latest
after
M 3275 400
D 08 engines —— —— 45,000 km 30,000 km 40,000 km 30,000 km after 600 operating
D 28 engines —— —— 60,000 km 45,000 km 40,000 km 30,000 km operating hours

M 3277 hours or or
D 08 engines —— —— 60,000 km 45,000 km 45,000 km 30,000 km 30,000 km 20,000 km
D 28 engines 80,000 km 60,000 km 80,000 km 60,000 km 60,000 km 45,000 km
M 3277 Trucknology Generation A (TGA) with flexible maintenance computer (including
TGA heavy-
D 08–CR engines ...... depending on application type, max. 60,000 km possible duty tractors
D 28 engines ...... depending on application type, max. 100,000 km possible H94, H95
D 20/28–CR engines ...... depending on application type, max. 120,000 km possible etc.)
M 3477
D 20–Euro 4 engines ...... depending on application type, max. 120,000 km possible
Gas engine oils (CNG / LPG)
M 3271 — Gas First engine oil change and filter change during running-in service after 1000 to 5000 km
E 28 engines (CNG) —— —— 30,000 km —— ——
G 28 engines (LPG) —— —— 30,000 km —— ——
Use of FAME as fuel (biodiesel), see page 30.

23
 ENGINE OIL CHANGE INTERVALS BASED ON MAINTENANCE GROUP

ENGINE OIL CHANGE INTERVALS FOR BUSES / COACHES, BUS / COACH CHASSIS FOC / HOC AND RAIL VEHICLES**
The engine oil change intervals indicated (pages 15 to 21) – summarised again in the following table for reasons of clarity – only apply to
approved engine oils.
Irrespective of the intervals indicated, the engine oil, oil filter and fuel filter must be changed at least once a year.

Maintenance group
Coaches and
Multigrade Coaches rail vehicles ** Buses Heavy-purpose
engine oils A+ A+ A A B B C C
to Works Standard .... Bypass oil filter * Bypass oil filter * Bypass oil filter * Bypass oil filter *
With Without With Without With Without With Without
Diesel engine oils
MAN 271
D 08 engines —— —— 35,000 km 20,000 km —— 30,000 km 12 months,
D 28 engines —— —— 45,000 km 30,000 km —— 30,000 km at the latest 12 months,
M 3275 after 600
D 08 engines —— —— 45,000 km 30,000 km 60,000 km 30,000 km operating at the latest
D 28 engines —— —— 60,000 km 45,000 km 60,000 km 30,000 km hours
M 3277 or 400
2)
D 08 engines —— —— 60,000 km 45,000 km 60,000 km 45,000 km 30,000 km operating
1) 1)
D 28 engines 80,000 km 60,000 km 80,000 km 60,000 km 60,000 km 45,000 km hours
Gas engine oils (CNG / LPG) or
M 3271 — Gas First engine oil change and filter change during running-in service after 1000 to 5000 km 20,000 km
E 28 engines (CNG) —— —— —— —— —— 30,000 km ——
G 28 engines (LPG) —— —— —— —— —— 30,000 km ——
1)
*) or 10-litre auxiliary tank for buses With flexible maintenance computer up to 100,000 km, CR 120,000 km possible
**) limited to rail cars (no locomotives) with application profile typical of a bus. Exceptions are subject to separate agreement with MAN.
2) 3)
including D08...– CR engines CRT filter, see page 26
Use of FAME as fuel (biodiesel), see page 30.

24
 SERVICE PRODUCTS

SERVICE PRODUCTS

For details regarding approved service product quality, refer to the "Item
name and specifications" column in the "SPECIFICATIONS" survey on
pages 39 to 58. The specifications in bold type generally indicate the
best quality service products available, which are recommended by MAN
and used for the factory fill.
The guarantee / warranty conditions stipulate the use of approved service
products since these products ensure the required level of performance.
If the stipulated quality is not available, approved alternatives are listed in
the "Alternative specifications" column. In such cases, the supplier or
manufacturer must provide a legally binding declaration which states that
the product fulfils the relevant MAN specifications in all respects.
If such products are used without MAN permission, the warranty /
guarantee shall be deemed null and void in the event of any damage.

Approval of service products

Service products are approved for a maximum of 2 years. If the supplier /
manufacturer so requests, we can extend the approval for a further two
years provided that the quality has not changed (see sample letter of
approval opposite).
Therefore, before purchasing a product, make sure that it is still
approved by having the supplier produce the letter of approval or
consult the MAN Intranet or MAN homepage on the internet:
→ http:\\www.man-mn.com
→ Products & Solutions
→ E-Business

25
SERVICE PRODUCTS

ENGINE OILS for ...... Engine oil additives

Approved oils for MAN diesel engines are only those engine oils
EURO 0, 1, 2 DIESEL ENGINES that have been tested to and which comply with Works Standard
Use multigrade engine oils (all-year-round oils) approved to MAN 270, 271, and M 3275 M 3277 or M 3477. The formula of
Works Standard MAN 271, M 3275 or M 3277. these oils is such that they fulfil normal operation requirements at
Only use single-grade engine oils to Works Standard MAN 270 all times if the specified oil change intervals are complied with.
if no multigrade engine oils are available. Additives of any kind whatsoever which are added to the engine oil
afterwards will alter the engine oil in unpredictable ways.
EURO 3 DIESEL ENGINES As the use of such additives may negatively affect engine perfor-
Only use multigrade engine oils approved to Works Standard mance, the extent of maintenance and engine service life, any
M 3277. warranty / guarantee claims against MAN Nutzfahrzeuge
Aktiengesellschaft shall be deemed null and void if the damage
EURO 4 DIESEL ENGINES can be traced back to the use of such additives.
Only use multigrade engine oils approved to Works Standard
M 3477.

Approved engine oils are listed on the Internet (see page 25).
Miscibility of engine oils
Do not mix different engine oils together unless the performance
Super-high-performance diesel engine oils capabilities of the oils are the same at the very least. This is to
to Works Standard M 3275, M 3277 or M 3477 prevent deterioration in the performance of the filled engine oil,
These oils have a considerably higher performance level than which would result in a shortening of the oil change interval.
engine oils to Works Standard MAN 270 and 271. Engine oils from different manufacturers can be mixed together
In supercharged diesel engines, super-high-performance diesel and are compatible provided they are for the same application
engine oils offer considerable advantages with regard to piston (diesel or gas engine oils, etc.).
cleanliness, wear and power reserves. In the interests of
increased life expectancy we therefore recommend the use of
these types of engine oils for supercharged engines. Super-high-
performance diesel engine oils are, of course, also suitable for
non-supercharged engines.
Approved super-high-performance diesel engine oils are listed on
the Internet (see page 25).

26
 SERVICE PRODUCTS

Diesel engines with particulate trap (CRT system): Viscosity regulations

In order to prolong the lifetime of the particulate trap, we SAE class dependent on the outside temperature.
recommend the use of engine oils to M 3477 or low-ash engine
oils to M 3277. Otherwise only low-sulphur diesel fuel SAE 15W - 40
(< 10 mg/kg sulphur) to DIN EN 590 is authorised for use.
The use of FAME (biodiesel) substantially shortens filter cleaning
SAE 10W - 40
intervals due to the higher incidence of ash caused by the ash- SAE 10W - 30
forming metals contained in FAME and damages the oxidation
activities of the catalytic converter because of the phosphorous SAE 5W - 30
and sulphur contents permitted in the standard. The system is
likely to fail in the long term. 0W - 30 SAE 5W - 40

Diesel engines with catalytic converter with particulate °C -30 -20 -10 0 +10 +25 +35
matter filter (Euro 4):
Only use engine oils to M 3477. Otherwise only low-sulphur
diesel fuel (< 50 mg/kg sulphur) to DIN EN 590 is authorised for
use. °F -22 -4 +14 +32 +50 +77 +95
The use of FAME (biodiesel) is not permitted, since this can
contain up to 10 mg/kg of ash-forming metals. SAE 20W - 20

Sulphur content in diesel fuel SAE 30

The oil and filter change intervals must be shortened, depending
SAE 40
on the sulphur content in the diesel fuel, as indicated on the
Exceptions:
following table.
If no MAN-approved engine oils are available, e.g. in certain
Deactivate the maintenance computer (TGA etc.), perform
countries, use engine oils for which the manufacturer or supplier
maintenance manually in accordance with ProFit-Check II as for
F2000 (FE–A). can produce written confirmation that the oil quality level at least
Sulphur content in Applicable engine oil Factor for shortening the
fulfils the requirements of ACEA E2, ACEA E3/E5 or ACEA E4 or
diesel fuel specification oil change interval API–CF–4/CG–4/CH–4/CI–4.
> 0.5% M 3277 0.50
If the engine oils indicated are used, the "ProFit-Check II" time-
> 0.5% MAN271/M3275 0.25
based maintenance system for L2000, M2000, LE–C/B, ME–B,
> 0.2% MAN271/M3275 0.50 F2000, FE–A and buses / coaches can only be used to a limited
> 0.2% API category 0.25 extent. Engine oil and filter changes must be in accordance with
CF-4, CG-4, CH-4 the relevant maintenance group. This means the engine oil, oil
> 0.2% M 3277 0.75 filter and fuel filter changes are due as follows: (see next
page)

27
 SERVICE PRODUCTS

Maintenance group A+ Only possible with approved engine oils to ENGINE OILS for CNG and LPG ENGINES
Works Standard M 3277
Only special gas engine oils approved to Works Standard
Maintenance group A Every 10,000 km for series D 08 M 3271–1 should be used for gas vehicle engines, although
engines preference should be given to multigrade engine oils (all-year-
round oils) due to their favourable cold-start characteristics.
Maintenance group A Every 15,000 km for series D 25/28 Here, too, it is not permitted to use additives with the engine oil –
engines see page 26, "Engine oils for diesel engines".
Maintenance group B 10,000 km Approved engine oils are listed on the Internet (see page 25).
Maintenance group C Every 6 months, at the latest after
200 operating hours or 10,000 km Engine oil change intervals
If CNG/LPG engines are used, the "ProFit-Check II" time-based
"ProFit-Check II" TGA / R02 / R03 maintenance system for L2000, M2000, LE–C/B, ME–B, F2000,
Use engine oils for which the manufacturer or supplier can FE–A and buses / coaches can only be used to a limited extent.
produce written confirmation that the oil performance level at least Engine oil and filter changes must be in accordance with the
fulfils the requirements of ACEA Oil Sequences E3/E5 or E4. relevant maintenance group. The following regular changes are
then necessary following the running-in service at 1000 to
In this instance, the maintenance computer must be set to engine 5000 km:
oil to Works Standard MAN 271, either by a MAN Service Maintenance group B: Every 30,000 km
workshop using MAN-cats II or by the driver.
Maintenance group C: Every 12 months, at the latest after
400 operating hours or 20,000 km
In the case of LPG vehicles, the gas filter must also be
changed when the engine oil and filter are changed.
Irrespective of the intervals indicated, the engine oil, oil filter and
gas filter must be changed at least once a year.

If none of the engine oils approved by MAN are available, approval

must be obtained from
MAN Nutzfahrzeuge Aktiengesellschaft,
Abt. MTVA
Vogelweiherstr. 33
D–90441 Nürnberg
before alternative products are used.

28
 SERVICE PRODUCTS

DIESEL FUEL addition to the "cold filter plugging point" (CFPP) usually specified
in the EN 590 standard include ensuring the lowest possible cloud
Diesel fuels to the following standards are suitable for the point (* CP) (see diagram)!
operation of MAN diesel engines:
– European Standard EN 590 Fuel recommendation for winter operation
– DIN EN 590 (Germany)
– British Standards BS 2869 Class A 1 (Great Britain)
– ÖNORM EN 590 (Austria) Arctic grade Cloud point < –25 °C (CP) *
– ASTM D 975 No. 1 D (U.S.A.)
Winter diesel grade DIN EN 590
(Nov. 16 – Feb. 29)
Diesel fuel – low-sulphur (< 350 mg/kg sulphur) / + Fuel filter heating
sulphur-free (< 10 mg/kg sulphur) to DIN EN 590
These diesel fuels may only be used if they contain additives Winter diesel grade DIN EN
which ensure adequate lubricity (request written confirmation from 590 (16. Nov. – 29. Febr.)
the supplier, see EN 590 for minimum requirements). Detergents
must generally be added to these low-sulphur / sulphur-free fuels Summer-grade
in order to prevent coking (carbon deposits) in the injection diesel
nozzles. Assurances for this must be provided by the fuel supplier
in order to ensure the correct balance and combination of lubricity °C –30 –20 –10 0
and detergent additives.
— Outside air temperature —
Winter operation (Germany) Do not add petrol!!
As ambient temperatures fall, diesel fuel deposits paraffin crystals
which increase the flow resistance in the fuel filter so much that an If the cold-flow behaviour of the diesel fuel is not
adequate fuel supply is no longer guaranteed.
adequate or if outside temperatures are even lower,
Summer-grade diesel to DIN EN 590 ensures operational reliability
we recommend installing a fuel filter heater.
down to 0 °C, winter-grade diesel fuel down to –10 °C.
Drain the fuel pre-filter and fuel tank as necessary
before the onset of winter.
To ensure trouble-free operation in winter, you must use winter-
grade diesel fuel for which the fuel manufacturer guarantees In countries where outside air temperatures are even lower
adequate operational reliability in addition to compliance with the than –20 °C, special diesel fuel (Alpine or Arctic grade) is
DIN standard! Decisive factors for ensuring operational reliability in usually available.

29
SERVICE PRODUCTS

Dangerous materials classes as per VbF (directive for There are certain points which must be observed:
combustible fluids) FAME has less favourable evaporating characteristics than diesel
Only applies to the Federal Republic of Germany. Observe the fuel. This leads to fuel dilution of the engine oil, a drop in
regulations in the country concerned. viscosity and, ultimately, increased engine wear. Therefore, the
engine oil change intervals (including engine oil filter and fuel
Diesel fuel / FAME:
filter change) for diesel fuel operation must be shortened as
− Dangerous materials class A III (flash point above 55 °C) follows:
Dangerous materials index figure 30
Material index figure 1202 Annual Engine oil, oil filter and fuel filter
mileage change in the case of FAME
Diesel fuel additives operation (due date / interval)
No fuel additives of any kind are necessary for the operation of
MAN diesel engines if the diesel fuel fulfils the requirements of the Up to max. 45,000 km Max. 20,000 km
above standards and specifications. or 600 operating hours or 400 operating hours
The use of such additives may negatively affect performance
characteristics, exhaust gas opacity, harmful emissions, More than 45,000 km Max. 30,000 km
extent of maintenance and service life of the engines. The
warranty given by MAN Nutzfahrzeuge Aktiengesellschaft is These stipulations similarly apply to alternate use of diesel fuel
therefore invalidated. and FAME as well as to mixtures of diesel fuel and FAME, which
are not covered by DIN EN 590.
Since FAME gels at low temperatures, we recommend the use of
Use of "biodiesel" (FAME) to DIN EN 14214: winter-grade diesel during the cold season.
(FAME = Fatty Acid Methyl Ester)
e.g. rape seed oil methylester (RME) Important!
All MAN engines can generally be operated with FAME, providing The use or addition of pure vegetable oils is not
this fuel meets the DIN EN 14214 standard and has been permitted!
produced using rape seed oil. The same applies to any so-called "alternative fuels"
There is currently no approval for FAME based on other which do not comply with the cited DIN EN 590 or
substances. DIN EN 14214 standards.

Common rail
Engines with CR injection are not currently
approved for operation with FAME!

30
 SERVICE PRODUCTS

Micro-organisms in the fuel system when using diesel fuel Both products are soluble in diesel fuel, bio diesel (FAME) and
and bio diesel (FAME) water. They do not produce corrosive combustion products. Their
Micro-organisms (bacteria, fungi, yeasts) present in diesel fuel and alkaline characteristics neutralise the acids formed by microbial
bio diesel (FAME) can multiply if the conditions are favourable for growth.
them. Such growth requires water (present as condensation in
every storage or vehicle fuel tank) and the presence of elements Instructions for use
essential for life in a chemically bonded form, such as sulphur,
phosphorous, nitrogen, oxygen and trace elements. Fuel additives Vehicle tank:
can also promote the growth of micro-organisms. Add 100 ml (0.1%) of disinfectant to 100 litres of diesel fuel or bio
Their growth rate depends on temperature and results in the diesel when filling up if sludge is visible or if the filter is clogged.
formation of fibrous fungal growths, sludge and microbial Repeat this procedure three times in all. Regularly check the
corrosion. primary fuel filter during use.
The consequences include rusting of the tank and clogging of the
main fuel filter or pre-filter with rust and biomass, meaning that the Storage tank:
filter has to be changed frequently. This reduces the engine power There is no need to flush out the tank if a check of the tank sump
and, in extreme cases, can immobilise the vehicle. fails to show any severe contamination by water or sludge. In this
case, it is sufficient to add 1 litre of disinfectant per cubic metre of
Remedial action the tank capacity.
We recommend using the following disinfectants to combat any
micro-organism build-up detected in storage or vehicle fuel tanks: Always refer to the EU safety data sheets (latest
editions) before using the disinfectants listed in the
Product: GrotaMar 71 left-hand column on this page.
Made by: Schülke & Mayr
D–22840 Norderstedt Contact the manufacturers if necessary (e.g. regarding sources for
( 0 40 / 521 00–0 obtaining the products outside Germany).
Fax: 0 40 / 521 00–244
or

Product: BAKZID
Made by: Bodechemie Hamburg
Melanchthonstr. 27
D–22525 Hamburg
( 0 40 / 540 06–0
Fax.: 0 40 / 540 06–200

31
SERVICE PRODUCTS

CNG USED AS FUEL Given the high heating value range, MAN Service personnel must
(CNG = Compressed Natural Gas) set the engine mixture formation system according to the quality of
natural gas used when CNG vehicles are commissioned. Similarly,
This gas is a natural resource. Its major constituents are methane, the system has to be reset if the quality is changed. Otherwise, the
ethane, propane and butane. It also contains traces of higher engine may malfunction.
hydrocarbons and inert components such as carbon dioxide and
nitrogen. The methane number is an important parameter for the engine.
The constitution of natural gas can fluctuate wildly, meaning that The methane number is a measure of the anti-knock quality of a
there may be considerable differences in its chemical / physical gas, comparable with the octane number of petrol. Knocking
values. combustion can cause engine damage or destruction. By
definition, hydrogen has a methane number of 0 and methane has
Natural gases are split into two groups depending on how they a methane number of 100. The methane number of natural gas is
burn: calculated from the relative size of the gas components and their
H gas (High, high heating value) and respective methane numbers.
L gas (Low, low heating value).
The methane number must not be confused with the methane
The grade of natural gas used in vehicles must comply with the content of the natural gas!
ECE–R 110 Directive.
CNG (compressed natural gas) is formed by compressing the
natural gas in a compressor under high pressure.
To cover times of high demand, some local gas
For MAN commercial vehicles the CNG fuel must show the providers mix the natural gas with liquid gas
following characteristic values: (propane, butane) or liquid gas / air mixes. This can
Density:
3
0.72 – 0.83 kg/m (at 0 °C and 1013 mbar) cause the methane number to fall to an
impermissibly low level and can result in engine
Heating
damage.
value: 40 – 50 MJ/kg
Minimum air You must ensure that mixes containing liquid gas or
requirement: 13.5 – 17.2 kg of air per kg of gas liquid gas / air mixes are never used, even for a
Methane limited period. We recommend that you obtain
number: 80 (70 if ignition point is adapted) confirmation from the gas provider.
Dew point: < –9 °C at a pressure of 200 bar
Water
3
content: < 32 mg/Nm
3
Oil content: < 10 mg/Nm

32
 SERVICE PRODUCTS

The engines with Venturi gas mixer are set to methane Its major constituents are propane, butane and small quantities of
number 80 before leaving the factory. This can be changed to propene, butenes and pentanes / pentenes.
methane number 70 if the ignition point is adapted. However,
this causes an increase in fuel consumption. Any such On visual inspection, LPG must be clear and free from
changes must be made by MAN Service personnel. undissolved water; it has a characteristic, unpleasant odour.
It is not possible to change the ignition point in engines with
For MAN commercial vehicles the LPG fuel must show the
the Motronic ME7–CNG0 gas injection system. These engines
following characteristic values:
are set to methane number 70.
Properties Unit of meas. Limit value
Most gas providers do not ensure the required dew point or
water content, meaning that the CNG filling station has to be Anti-knock value ....................... MOZ....................... Min. 92.5
equipped with a gas dryer. If the dew point is exceeded, this Odour ....................................... ............................... Specific and
can significantly reduce the checking interval for the pressure unpleasant
vessels as well as causing problems when filling up (hydrate Diene content (as 1.3 butadienes)
formation). Mol%...................... < 0.5

Oil in the natural gas may be due to the lubricating oil in the Total sulphur content ................ mg/kg..................... < 200
CNG filling station's natural gas compressor. It must be
Corrosive effect on copper
ensured that the CNG filling station has a sufficiently large (1 h at 40 °C) ............................ Corrosion grade..... 1
and functioning oil separator system.
Solid residue from evaporation . mg/kg..................... < 100
In the event of deviating characteristic values, approval for
the natural gas is to be obtained from MAN Nutzfahrzeuge Vapour pressure, abs. at 40 °C kPa ........................ > 1550
Aktiengesellschaft, dept. MTVA–N, Vogelweiherstr. 33, Minimum vapour pressure, absolute
D–90441 Nürnberg. at 5 °C from 16.11 to 28.02....... kPa ........................ < 250

In the event of deviating characteristic values, approval for the

liquid gas is to be obtained from MAN Nutzfahrzeuge
LPG USED AS FUEL Aktiengesellschaft, dept. MTVA–N, Vogelweiherstr. 33,
(LPG = Liquefied Petroleum Gas) D–90441 Nürnberg.
LPG is a mixture of volatile, liquid hydrocarbons stored in a liquid
state at room temperature and low pressure.

33
SERVICE PRODUCTS

OPERATION WITH AVIATION TURBINE FUEL (KEROSENE)

Jet A 1, F-34, F-35, F-63

Density at 15 °C:.................... 0.775 to 0.845 g/ml

Boiling range:......................... 130 to 300 °C
Freezing point: ....................... Max. –47 °C
Cetane index:......................... Not defined

In principle, MAN engines with oil-lubricated in-line injection

pumps can be operated with aviation turbine fuel. It is not
permitted to operate engines with the above fuels if they are
fitted with mechanically and electrically controlled
distributor-type injection pumps (VE.., VP 44 ...) and common-
rail injection system. The lower density and viscosity, coupled
with the boiling range and lack of lubricity compared to diesel fuel,
means that reduced engine power, increased leakage at the
injection pump and a shorter injection system lifetime are all to be
expected.
Further disadvantages include poorer engine starting
characteristics as well as worse emission levels.

Note: Technical clarification with MAN is required in the case of

special-purpose applications using these fuels (MIL).

34
 SERVICE PRODUCTS

COOLANT No mixing!
Coolants to MAN 324 type SNF must not be mixed
Antifreeze, anti-corrosion protection and anti-cavitation with type N or type NF coolants!
protection to MAN 324 for the engine cooling system and
heating system Anti-corrosion agent (without antifreeze)
For protection against corrosion, cavitation and cold, the cooling If it is not possible to use antifreeze for certain applications, use
and heating systems of all vehicles are, all year round, factory- anti-corrosion agents to Works Standard MAN 248.
filled with a mixture of 40% antifreeze (by volume) and 60%
potable mains water (by volume), offering frost protection down to Details of the application and product-specific concentration can
–27 °C. be found in the service products database on the Internet (see
You must use at least 40% antifreeze (by volume) in the mix in page 25).
order to ensure adequate anti-corrosion protection. When carrying
out maintenance work, increase the antifreeze in the mix to 50%
by volume (–37 °C) in order to provide adequate "reserves" should No mixing!
water need to be added later. Anti-corrosion agents to MAN 248 must not be
However, you should avoid using more than 50% antifreeze (by mixed with antifreeze or coolants to MAN 324!
volume) in the mix.
The cooling and heating systems have been designed so that, in
Central Europe, coolant containing 40% to 50% antifreeze (by
volume) does not need to be drained in the summer.
Antifreeze, anti-corrosion protection and anti-cavitation
Before the onset of cold weather, use the table below to alter the protection for MAN–Voith PriTarder (water retarder) to MAN
mix to take into account lower temperatures. 324 NF (TGA)
Important!
Mixing table:
Only specially approved antifreeze mixed 50 : 50
Outside air Antifreeze Water with drinking water may be used (see service
temperature products database on the Internet. Also refer to the
down to ... information on the inside of the cover sheet or
–27 °C................. 40% by volume ........ 60% by volume page 25)
–31 °C................. 45% by volume ........ 55% by volume
–37 °C................. 50% by volume ........ 50% by volume

Ready-mixed antifreeze and water – consisting of at least 40% (by

volume) approved antifreeze and deionised water – is permitted.

35
SERVICE PRODUCTS

Changing the coolant WATER QUALITY

Coolant with antifreeze MAN 324: Unsuitable or inadequately or incorrectly prepared coolants may
− Change every 4 years; however, every 500,000 km at the latest cause cooling system elements to fail as a result of cavitation or
corrosion. Furthermore, heat-insulating deposits may form on
heat-conducting elements such as cylinder liners, cylinder heads,
Coolant with anti-corrosion agent MAN 248 (without antifreeze): oil coolers and radiator fins, causing overheating and, ultimately,
− Renew every year engine failure.
For reliable operation of MAN engines, the coolant must – in
addition to the antifreeze / anti-corrosion agent specified on the
Regardless of these intervals, change the coolant previous page – contain potable mains water which at least fulfils
immediately if it has turned brown or cloudy. the following minimum requirements.

Every 4 years, fit new pressure-relief valve caps and filler / Analysis values:
sealing caps on the expansion tank (with the exception of Appearance ........................ colourless, clear, free from
screw caps) at the same time as changing the coolant. mechanical impurities
Total hardness .................... max. 20° German hardness
^ 35.6° French hardness
^ 25° British hardness
Disposal
Treat undiluted antifreeze / anti-corrosion agent as hazardous ^ 358 ppm USA hardness
waste. Chloride .............................. max. 100 mg/l
Follow the instructions issued by the relevant local authority when Sulphate.............................. max. 150 mg/l
disposing of used coolant (mixture of antifreeze / anti-corrosion pH value at 20 °C................ 6.5 to 8.5
agent and tap water).
There are disposal companies that specialise in the recycling of You should obtain analysis values for potable water from the
coolant containing antifreeze, concentrated antifreeze and brake relevant local authorities.
fluid. If you decide to use these companies, you must collect the If mains water of this quality is not available, the available water
product groups separately and not mix them with different types of should be mixed with condensed or fully desalinated water until
service products (oils, solvents, fuels). the above analysis values are reached.
Fully desalinated water, distilled water and condensed water are
also suitable.

Sea water, brackish water and waste water are unsuitable.

36
 SERVICE PRODUCTS

GEAR OILS Gear oils to Works Standard MAN 341 / 342 or M 3343
High-pressure gear oils specified and approved to Works Standard
Gear oil change intervals MAN 341, extreme-pressure gear oils specified and approved to
Manual gearbox, automatic gearbox, transfer case and MAN 342 and multifunction gear oils specified and approved to
retarder M 3343 (fulfilling the requirements of MAN 341 and MAN 342)
The oil change intervals (pages 15 to 21) apply to Central exceed the minimum MIL and API requirements.
European conditions. Shorten the change intervals in areas where Gearbox oils to works standard MAN 341 are classified as type N,
temperatures are higher if necessary. Consult your local MAN ML, TL, SL and SL+, gearbox oils to MAN 342 are classified as
Service workshop for advice. type N, ML and SL, gearbox oils to M 3343 are classified as ML
Synchromesh gearboxes can also be filled with SAE 85W-90 or and SL.
SAE 90 in hot countries. Gear shift quality may deteriorate if these Meaning of the type codes:
oils are used in temperate zones. The best choice for the unit is Type N: mineral, normal change interval
the fully synthetic gear oil indicated in the "SL or SL+" Type ML: mineral, longer change interval
specification. Type TL: semi-synthetic, longer change interval
See "Specifications" on pages 41 to 43 for information regarding Type SL: fully-synthetic, longer change interval
the use of engine oils in gearboxes.
Only approved gear oils guarantee perfect gear shifts in
synchromesh gearboxes, sufficient protection against ageing and
Viscosity regulations wear on driven axles or other applications listed in the
The SAE class is dependent on the outside temperature. "Specifications" survey.
Worldwide availability of the approved gear oils listed on the
SAE 85W - 90 and SAE 90 Internet (see page 25) is guaranteed.

SAE 80W Application

− Only gearbox oils to MAN 341 or M 3343 (see "Specifications"
SAE 80W - 90 on page 42 for restrictions) may be used in ZF / Eaton
synchromesh gearboxes, ZF gearboxes with synchronised
SAE 75W - 90 splitter or range-change and ZFAS-Tronic gearboxes; only
MAN 341 type SL+ for ZF TC-Tronic gearboxes.
SAE 75W - 80W
− Only gear oils to MAN 341, type SL or TL, may be used for ZF
°C -40 -26 -12 0 +21 +30 +38 synchromesh gearboxes with ZF secondary retarder or
ZF-Intarder (exception: engine oil to MAN 270, SAE 30 – see
specifications).
°F -40 -13 +10 +32 +70 +86 +100 ðð continued ðð

37
SERVICE PRODUCTS

− Use gear oils to MAN 341, MAN 342 or M 3343 in Eaton–Fuller HYDRAULIC FLUIDS (to M 3289 ZHF)
manual gearboxes (not Eaton synchromesh gearboxes) as well Hydraulic fluids to M 3289 ZHF must never be mixed with brake
as those with synchronised range-change. fluid. The products each have a different basis and are neither
− Only use gear oils to MAN 342 type N, ML and SL or M 3343 miscible nor compatible. Mixing or topping up with ATF is not
type ML and SL for driven axles. possible due to the different characteristic data (e.g. viscosity,
The use of gear oils to MAN 341 is no longer authorised. viscosity index etc.).
− Vehicles in which the maintenance intervals are to be fully used
require higher performance lubricants with improved additive CLEANING THE OUTSIDE OF VEHICLES AND MAJOR
and base oil technology. COMPONENTS
Only gearbox oil types SL or SL+ are permitted for these The use of high-pressure cleaners, tap water and suitable cleaning
vehicles. products is permitted if the following conditions are fulfilled:
− High-pressure cleaner with flat aperture nozzle, spray angle 25°
− Operating pressure: max. 50 bar
The considerably longer change intervals are only − Temperature: Non-heated (cold) or up to max. 50 °C
possible if the indicated gear oils to Works Standard − Minimum jet-to-surface distance: 50 cm
and the products approved and named by this − Cleaning solution 1–5%,
standard are used. Using any other products may e.g. cleaning products such as Henkel P3-T 9275, P3-glin,
result in serious damage and renders any Kluthe Hakopur 50 etc. (pH value: < 9.5 of the 1% mix)
guarantee / warranty claims against MAN
Nutzfahrzeuge AG null and void. Danger of component damage!
Do not direct the jet at engine intake opening(s) or at
vents and breathers for axles and gearbox.
The cleaners are self-demulsifying (self-diluting).
The cleaning water can be disposed of via an oil separator. The
AUTOMATIC TRANSMISSION FLUID (ATF) resistance properties of enamel, plastic parts and underbody
Automatic gearbox protection are guaranteed if the above conditions are fulfilled.
Always drain all the oil, including from the heat exchanger, when
changing the ATF type in automatic gearboxes. Prohibited:
− So-called "water cannons, power jets or dirt blasters"
Avoid mixing different types of ATF with each other. − Hydrocarbon-based cold cleaners (cleaning-grade spirits) and
other solvent-containing cleaners added to water.
− Direct high-pressure cleaning of electrical connections,
Approved ATF products are listed on the Internet (see page 25). connectors etc.

38
 SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

DIESEL ENGINE
Lubrication..................... Initial fill Running-in engine oil M 3291
Euro 0, 1, 2 and 3................... SAE 10W–40 ............................................ None
(M 3291 has the same performance
capability as M 3277)
Initial fill Running-in engine oil M 3491
Euro 4..................................... SAE 10W–40 ............................................ None
(M 3491 has the same performance
capability as M 3477)
Service fill Super-high-performance diesel engine oil
Euro 0, 1 and 2....................... to M 3277 .................................................. ACEA E4
see pages 26/27 Alternatively:
Super-high-performance diesel engine oil
to M 3275 .................................................. ACEA E3/E5
or Engine oil to MAN 271 .......................... ACEA E2
Service fill
Euro 3..................................... Super-high-performance diesel engine oil
see pages 26/27 to M 3277 .................................................. ACEA E4
Service fill
Euro 4..................................... Super-high-performance diesel engine oil
see pages 26/27 to M 3477 .................................................. None
In extremely cold
application conditions...... Down to –32 °C ......................Super-high-performance diesel engine oil
(use pre-heating system at Viscosity class........................................... ACEA E4
temperatures below –32 °C) SAE 0W–30, 5W–30, 5W–40
Cooling........................... Cooling system.......................Antifreeze MAN 324.................................. None
Antifreeze and anti-corrosion or
protection, see page 35 Anti-corrosion agent MAN 248 ................. None
+ potable tap water
Hydrostatic fan drive............... Engine oil
same as diesel engine .............................. Engine oil
same as diesel engine
Fuel................................. Winter operation, ASTM D 975 No. 1 D
see page 29............................ Diesel fuel DIN EN 590 ............................. BS 2869 Class A 1
EN 590
ÖNORM EN 590
Initial fill service product in bold type. 39
SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

GAS ENGINE
(CNG/LPG)

Lubrication ..................... Service fill, ............................. Gas engine oil M 3271–1 .......................... None
see page 28 for
application range.
Cooling ........................... Cooling system ...................... Antifreeze MAN 324 .................................. None
see page 35 for antifreeze or
and anti-corrosion protection Anti-corrosion agent MAN 248 ................. None
+ potable tap water
Fuel ................................. See page 32 – 33 .................. Compressed natural gas (CNG)................ None
or liquefied petroleum gas (LPG) .............. None
GEARBOX

Manual gearbox ............. ZF synchromesh gearbox (S), High-pressure gear oil MAN 341 type N**,
1)
constant-mesh gearbox (K) ML*, TL*, SL*, SL+
with synchronised splitter SAE 80W, 80W-90 or 75W-90 .................. MIL–L–2105 (API–GL 4)
and/or range-change or
ZF–NMV . . ./1 Multifunction gear oil M 3343 type ML*,
(see next page for exceptions) SL*
as well as SAE 80W-90, 75W-90 ............................... MIL–L–2105 D (API–GL 4 + 5)
Eaton synchromesh gearbox,
Eaton Samt B and Eaton See ZF List of Lubricants TE–ML 02! ZF gearbox: Engine oil MAN 270
AutoShift 16 gearbox SAE 30 **

ZF synchromesh gearbox
High-pressure gear oil MAN 341
1)
with ZF secondary retarder or
type TL*, SL*, SL+ ................................... None
ZF-Intarder SAE 75W–80W or 75W-85W *
Alternatively:
Engine oil MAN 270 SAE 30 **.................. Same engine oil as diesel engine
(no multigrade oil)
See ZF List of Lubricants TE–ML 02!
* Specified for maintenance group "A+" ** not approved in the case of maintenance group "A+" or TIPMATIC (ZF AS Tronic)
1)
Specified for TGA gearbox with oil change interval 500,000 km

40 Initial fill service product in bold type.

 SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

Manual gearbox............. ZF synchromesh gearbox ATF MAN 339 type D ................................ ATF Dexron II
(continued) Buses and coaches: Alternatively
S 6 – 36 or S 6 – 85 ATF MAN 339 type F ................................ ATF Dexron III
(oil change every 30,000 km)
Trucks:
S 6 – 36 or S 5 – 42 possible See ZF List of Lubricants TE–ML 02!
after E service due to
reduced gearshift effort
(oil change as MAN 270)
In extremely cold
application conditions...... Down to –50 °C ...................... Gear oil MAN 341 / M 3343 all type SL
SAE 75W-85W, 75W-90 ........................... None

ZF constant-mesh High pressure gear oil MAN 341

gearbox (K) type N, ML, TL, SL .................................... MIL–L–2105 (API–GL 4)
non-synchronised
Alternatively:
and Extreme-pressure gear oil MAN 342
type N, ML, SL .......................................... MIL–L–2105C/D (API–GL 5)
Eaton and Twin Splitter /
Samt–A gearbox or
Multifunction gear oil M 3343
(not Eaton synchromesh, type ML, SL ............................................... MIL–L–2105D (API–GL 4 + 5)
Samt–B and AutoShift 16 SAE 80W, 90, 80W–90, 75W-90
gearbox)
Alternatively:
Engine oil MAN 270 SAE 30 or 40............ Same engine oil as diesel engine
(no multigrade oil)
See ZF List of Lubricants TE–ML 02!
In extremely cold
application conditions...... Down to –50 °C ...................... Gear oil MAN 341 / M 3343 all type SL
SAE 75W-85W, 75W-90 ........................... None

ZF Duo Drive HZA.......... In gearbox ZF S 5–42............. Castrol Syntrans gear oil only ................. None
(Hydrostat) (veh. type 10.163 LAEC–GT)

Initial fill service product in bold type. 41

 SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

GEARBOX
(continued)

Automated manual
gearbox........................... TIPMATIC High-pressure gear oil MAN 341 type N,
1)
TGA (ZF AS–Tronic 1 + 2) ............. ML, TL, SL, SL+
without ZF-Intarder SAE 80W, 75W-85W, 80W-90, 75W-90.... MIL–L–2105 (API–GL 4)
or
)
Multifunction gear oil M 3343 * type ML,
SL; SAE 80W-90, 75W-90......................... MIL–L–2105 D (API–GL 4 + 5)

See ZF List of Lubricants TE–ML 02! *) only for ZF AS–Tronic 1 without

Intarder

TGA, R02 / R03 TIPMATIC (ZF AS–Tronic) .... High-pressure gear oil MAN 341
1)
with ZF-Intarder type TL, SL, SL+ ..................................... MIL–L–2105 (API–GL 4)
SAE 75W–80W or 75W-85W

See ZF List of Lubricants TE–ML 02!

In extremely cold
application conditions ...... Down to –50°C....................... Gear oil MAN 341, all type SL
(ZF AS Tronic) SAE 75W-85W, 75W-90............................ None

TGA heavy-duty
transport vehicles.......... ZF TC–Tronic gearbox........... High-pressure gear oil MAN 341, Typ SL+. None

See ZF List of Lubricants TE–ML 02!

Automatic
gearbox........................... Voith Diwa gearbox 506......... Approved engine oils SAE 20W–20,
15W–40 or 10W–40 .................................. None

as per Voith List of Lubricants 55.6335.32

(G–607).
1)
specified in the case of TGA with TIPMATIC gearbox (ZF AS Tronic) and oil change interval of 500,000 km

42 Initial fill service product in bold type.

 SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

Automatic
gearbox .......................... Voith Diwa gearbox 851 to ATF MAN 339 type D ............................... ATF Dexron II
(continued) 864.3 E Alternatively:
and ATF MAN 339 type F................................ ATF Dexron III
Midimat BR (gearbox only,
see page 46 for retarder) (factory fill synthetic)

See Voith List of Lubricants 55.6335.32

(G–607) and 55.6336.32 (G–1363)!
In extremely cold
application conditions...... Down to –45 °C ...................... ATF MAN 339 type F only
(Voith Diwa gearbox) Castrol Transmax Z or
Veedol Unitrans Z ..................................... None
ZF–Transmatic gearbox ........ Engine oil MAN 270 SAE 30 ..................... Same engine oil as diesel engine
with WSK (torque converter (no multigrade oil)
and clutch system) and new See ZF List of Lubricants TE–ML 02!
ZF WSK 440 (TC2) with
separate oil circuit
ZF WSK.................................. ATF MAN 339 type D ................................ ATF Dexron II
(with integral oil circuit) Alternatively:
ATF MAN 339 type F ................................ ATF Dexron III
Only use ATF at or
temperatures down to –40 °C Engine oil MAN 270 SAE 30
Alternatively: SAE 20W-20........................ Same engine oil as diesel engine
(no multigrade oil)
See ZF List of Lubricants TE–ML 02!
ZF–ECOMAT, type 4, 5 or 6
HP 500/502/590/592/600/602 ATF MAN 339 type D ............................... None
/902 Alternatively:
as well as ATF MAN 339 type F................................ None
ZF gearbox with converter (factory fill synthetic)
HP, HM
See ZF List of Lubricants TE–ML 14!
In extremely cold ATF MAN 339 type F only
application conditions...... Down to –45 °C ...................... Castrol Transmax Z, Veedol Unitrans Z or
(ZF–ECOMAT) ZF Ecofluid A ............................................ None

Initial fill service product in bold type. 43

SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

Automatic
gearbox........................... Renk REMAT automatic
(continued) gearbox.................................. Engine oil MAN 270, SAE 10W ................. Engine oil ACEA E2
type HS, WR–PS Alternatively: FZG A/8,3/90 ≥ 11th damage load
SAE 5W–30 (O–1178) stage

Allison gearbox
type AT / MT / HT .................. ATF MAN 339 type D or F......................... ATF Dexron II or Dexron III
(Allison type C 4 fluid)

Type CLT / CLBT 754 – 755.. Engine oil MAN 270, SAE 30 .................... ACEA E2
Dropbox ............................... Alternatively:
Engine oil MAN 271, SAE 15W–40 ........... ACEA E2
or
Engine oil M 3275, SAE 15W–40 .............. ACEA E3

Comply with Allison oil specifications and

application temperature!

Cable winch gearbox .... Rotzler only............................ Extreme-pressure gear oil MAN 342
Only applicable to drum type N, ML, SL........................................... MIL–L–2105C/D (API–GL 5)
winches (H–types) or
Treibmatic winches (T-types) Multifunction gear oil M 3343
are lifetime-lubricated type ML, SL ............................................... MIL–L–2105 D (API–GL 4 + 5)
(use the same service products when
the unit comes in for repair)
SAE 80W, 90, 80W–90 or 75W-90

(observe winch type plate!)

MAN transfer case ......... G 102/103/172/173/252/253 .. Extreme-pressure gear oil MAN 342
type SL, 75W–90....................................... MIL–L–2105C/D (API–GL 5)

44 Initial fill service product in bold type.

 SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

MAN transfer case......... G 1000, G 1700, G 2500 ........ Extreme-pressure gear oil MAN 342
(continued) VG 750 (ADM) type N, ML, SL .......................................... MIL–L–2105C/D (API–GL 5)
or or
Multifunction gear oil M 3343
type ML, SL ............................................... MIL–L–2105 D (API–GL 4 + 5)

SAE 80W, 90, 80W–90 or 75W90

ZF/STEYR transfer
case ................................ VG1600 (ADM)....................... Gear oil MAN 342 type N
(flange-mounted on SAE 85W-90 ............................................. MIL–L–2105 B/C (API–GL 5)
HP902)
In extremely cold
application conditions...... Down to –50 °C ...................... Gear oil MAN 342, M 3343 all type SL
SAE 75W-85W, 75W-90 ........................... MIL–L–2105 D (API–GL 5)
MIL–L–2105 D (API–GL 4+5)
Steering gear ................. Mechanical steering ............... Extreme-pressure gear oil MAN 342
including ZF bevel drive type N, ML, SL .......................................... MIL–L–2105C/D (API–GL 5)
or
Multifunction gear oil M 3343
type ML, SL ............................................... MIL–L–2105 D (API–GL 4 + 5)

SAE 80W, 80W–90, 90 or 75W–90

ZF, Bendix and RBL power ATF MAN 339 type D ................................ ATF Dexron II
steering; including ZF bevel Alternatively:
drive ATF MAN 339 type F ................................ ATF Dexron III

ZF power steering and ZF

bevel drive .............................. Hydraulic oil TL 9150–0035, H–540.......... None
(for SX 90 / SX 2000 vehicles
only)

Steering gear / trailing

axle steering .................. Power steering including
TGA trailing axle steering ZF
®
RAS EC 1 ............................. ATF MAN 339 type D/F ............................ ATF Dexron II / III

Initial fill service product in bold type. 45

SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

RETARDER

Voith................................ Voith 120–2, 130, 133,

R 115 ..................................... Engine oil M 3275*, M 3277*
(synthetic / semi-synthetic)
SAE 5W–30, 5W–40, 10W–40 .................. ACEA E3, ACEA E4,
SAE 5W–30, 5W–40, 10W–40
See Voith list of lubricants 67.2246.11!
In extremely cold
application conditions ...... Voith 120–2, 130, 133, R 115 Castrol Transmax Z or
Veedol Unitrans Z...................................... None

Telma .............................. TELMA................................... Supertelmaco III ........................................ Lithium complex grease

eddy current brake NLGI class 2
(e.g. Esso Unirex N 2,
Elf Multi HT2,
Shell Albida RL 2)

ZF .................................... ZF synchromesh gearbox ...... Engine oil MAN 270 SAE 30 **.................. Same engine oil as diesel engine
with ZF secondary retarder (no multigrade oil)
or Alternatively:
ZF-Intarder
High pressure gear oil MAN 341
type TL*, SL* ............................................. None
SAE 75W–80W or 75W-85W *

See ZF List of Lubricants TE–ML 02!

MAN–Voith...................... Pritarder (water retarder) Antifreeze MAN 324 NF *)......................... None

+ potable tap water
(mixed 50 : 50 by volume)

*) only approved products, see service

products database on the Internet
* Specified for maintenance group "A+" ** Not approved for maintenance group "A+"
46 Initial fill service product in bold type.
 SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

AXLES

Driven axles ................... Hypoid axles, ......................... Extreme-pressure gear oil MAN 342
1)
driven axles for buses and type N**, ML* or SL* .............................. MIL–L–2105C/D (API–GL 5)
coaches (not HONP .....) or
Multifunction gear oil M 3343
type ML* or SL* ........................................ MIL–L–2105 D (API–GL 4 + 5)
SAE 80W–90, 90 or 75W-90
MAN–ZF portal axle Extreme-pressure gear oil MAN 342
HONP..... ................................ type ML or SL............................................ MIL–L–2105C/D (API–GL 5)
(AV131/132) or
Multifunction gear oil M 3343
type ML or SL............................................ MIL–L–2105 D (API–GL 4 + 5)
SAE 80W–90, 90 or 75W-90
See ZF List of Lubricants TE–ML 12!
Other ...................................... Extreme-pressure gear oil MAN 342
− planetary axles (AP) type N, ML or SL ....................................... MIL–L–2105C/D (API–GL 5)
− spur gear axles
− power divider Alternatively:
− steering knuckle bearings
on the front planetary axles Multifunction gear oil M 3343
(AP) type ML or SL............................................ MIL–L–2105 D (API–GL 4 + 5)

Driven trailing axles ...... HAA–0950 L SAE 80W–90, 90 or 75W-90

In extremely cold
application conditions...... Gear oils for all ...................... Extr.-pressure gear oil MAN 342 type SL . None
driven axles:
Down to –50 °C Alternatively:

Multifunction gear oil M 3343 type SL ....... None

SAE 75W–90 or 75W-85W

* Specified for maintenance group "A+" ** Not approved for maintenance group "A+"
1)
Specified for TGA hypoid axle HY–1350 with oil change interval 500,000 km

Initial fill service product in bold type. 47

SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

AXLES
(continued)

Non-driven axles

Oil fill: Wheel hub .......... Axles V7/9–90L, HOM...., Extreme-pressure gear oil MAN 342
HONG.... type N, ML, SL........................................... MIL–L–2105C/D (API–GL 5)
or
Spring bearings ............. Heavy-duty tandem axles Multifunction gear oil M 3343
(F 90, F 2000) type ML, SL ............................................... MIL–L–2105 D (API–GL 4 + 5)
SAE 80W–90, 90 or 75W-90

Grease fill: Wheel hub... − Front axles (not Hub Unit).. High-temperature grease
− Leading and trailing axles .. MAN 284 Li–H 2........................................ Lithium complex grease with
− Portal axles HONP–1300, mineral oil,
HONP–13100 .................... NLGI class 2,
drop point at least 230 °C

Grease fill: Steering

knuckle bearings ........... Front, leading and trailing
TGA axles maintenance free; for
repair only .............................. Special grease
Fuchs / DEA Renolit LX–OTP 2 .............. None

Driven and non-driven

axles

Wheel hub ...................... Wheel bearing units ............... High-temperature grease

Hub Units = maintenance- MAN 284 Li–H 2 ........................................ Lithium complex grease with
free; for repair only mineral oil,
(Factory Fill MAN 284 Li–H 3) NLGI class 2,
drop point at least 230 °C

48 Initial fill service product in bold type.

 SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

HYDRAULIC SYSTEMS

Leading, trailing and

®
rear axle steering .......... ZF Servocom RAS .............. Central hydraulic fluid M 3289 ZHF *) ....... None
(veh. type T06, T35, T36,
RAS = Rear Axle Steering T37, A54)
®
HS = Hydrostatic Steering ZF Servocom RAS EC1 ...... ATF MAN 339 type D/F ............................ ATF Dexron II / III
(veh. type E65, E73, A25,
A26, A30)
®
ZF Servocom RAS EC3 ...... ATF MAN 339 type D/F ............................ ATF Dexron II / III
(veh. type E72, E74, E77,
E78, E79) and
ZF Servocom HS .................. ATF MAN 339 type D/F ............................ ATF Dexron II / III
(veh. type E47, E53, E63,
E67) See ZF List of Lubricants TE–ML 09! *) also, in some cases, front axle
steering filled with M 3289 ZHF

Leading or trailing
axle steering / steering
gear................................. Power steering including
TGA leading or trailing axle
steering
®
ZF Servocom RAS EC 1
(H23, H24, H94, H95)............. ATF MAN 339 type D/F ............................ ATF Dexron II / III
®
ZF Servocom RAS (H17 to
H21) See ZF List of Lubricants TE–ML 09!

Cab hydraulic
tilting mechanism.......... –30 °C to +65 °C .................... Hydraulic oil DIN 51524–HVLP 15 ............ None
(also TGA) Alternatively:
–54 °C to +71 °C .................... Hydraulic oil M 3325.................................. TL 9150–0020, H–515

Initial fill service product in bold type. 49

SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

HYDRAULIC SYSTEMS
(continued)

Implement hydraulics
(SX 90 / SX 2000)............ –30 °C to +65 °C.................... Hydraulic oil TL 9150–0035 H–540 ........... None
Cable winch and crane Alternatively:
(shared oil circuit) –35 °C to +75 °C.................... Central hydraulic system fluid
M 3289 ZHF .............................................. None
and

Central hydraulic
system
(LX 90 / SX 2000): ..........
Fan drive, ZF power
steering, cable winch,
crane (shared oil circuit)

Central hydraulic
system
Heavy-duty tractor ........... Type E94, E95, E98, E99 ...... Multigrade hydraulic oil H–575
Semitrailer / artic. (equivalent to MIL–L–17111) .................... Single-grade hydraulic oil
hydraulic system e.g. OMV hyd OHA32 DIN 51524 HLP – 32
shared oil circuit............... Type E68, E69, E75, T44 ...... or
separate oil circuit............ Type H94, H95....................... DIN 51524 HLP – 46

Brake and clutch

actuator .......................... ............................................... Brake fluid FMVSS 116 DOT 3, DOT 4
or DOT 5.1................................................. SAE J 1703, ISO 4925
Boiling point at least 260 °C
Clutch actuator and
Kongsberg gear change
system ............................ –35 °C to +75 °C.................... Central hydraulic system fluid
(shift assistance) TGA M 3289 ZHF .............................................. None

50 Initial fill service product in bold type.

 SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

HYDRAULIC SYSTEMS
(continued)

Anti-jackknife system ... (Articulated buses type 793 /

890) ........................................ ATF MAN 339 type D ................................ ATF Dexron II
Alternatively:
ATF MAN 339 type F ................................ ATF Dexron III

Anti-jackknife system ... (Articulated buses type A11 /

SKD 540 / 420 A18 / A19 / A23 / A24)............ Engine oil MAN 270, SAE 10W................. Engine oil the same as diesel
engine and Renk REMAT
gearbox
Tipper hydraulics *........
Refuse vehicle
hydraulics
Central hydraulic
system:
(production vehicles) –10 °C to +80 °C .................... ATF MAN 339 type D ................................ ATF Dexron II
Alternatively:
Crane and cable winch ATF MAN 339 type F ................................ ATF Dexron III
(shared oil circuit) –15 °C to +80 °C .................... or
Hydraulic oil DIN 51524 H–LP 22 ............. None
or
Hydraulic oil N 698 H–LPD 22 .................. None
*) When operating at temperatures below –5 °C, allow tipper hydraulics to warm up or work at idling speed.

Lifting axle, hydraulic ... (Vehicle type E 12, 75, 95) ..... Shock absorber oil: Aral Vitamol 1010...... None

Suspension, hydraulic.. (Vehicle type E 72, 74, 77,

78, 79) .................................... ATF MAN 339 type D ................................ ATF Dexron II
Alternatively:
ATF MAN 339 type F ................................ ATF Dexron III

Initial fill service product in bold type. 51

SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

GREASING POINTS

Periodic lubrication ....... Operating temperature up

to 130 °C ............................... Multipurpose grease MAN 283 Li–P 2....... Multipurpose grease (Lithium–12–
All nipple-type and loose-type hydroxistearate type)
greasing points such as: + EP additives, NLGI class 2,
Linkages and cables, engine drop point at least 180 °C
control, clutch and gearshift,
tipper pins, spare wheel hoist, Without solid lubricants
cab tilt mechanism: Locking (graphite, MoS2)
mechanism, carrier frame for
interchangeable bodies: Main
bearing journal thread,
centring roller mounts, brake
camshaft bearings on rear
axle, spring pins, slack
adjuster and ball joints etc.

Important! Lubricate steering

knuckles and grease wheel
bearings / wheel hubs
MAN 284 Li–H 2,
see page 48

In extremely cold
application conditions ...... Down to –50 °C...................... DEA Discor 8 EP 2 .................................... Lithium complex grease with
synthetic base oil,
NLGI class 2,
drop point at least 230 °C

52 Initial fill service product in bold type.

 SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

Periodic lubrication....... Lubrication of vehicle door
(continued) locks, outside handle.............. Fuchs RENOCAL FN 745/94
(locking cylinder grease) (MAN No.: 09.15004–0027) ...................... Water-resistant lubricating
Optitemp TT 1 (spray) grease, NLGI class 1/2,
(MAN No.: 09.15014–0024) ...................... drop point at least 120 °C
Operating temperature up
to 150 °C ................................ Long-life grease: Olista Longtime 3EP ..... None
Gearbox input shaft splines (1 kg MAN no.: 09.15001-0108,
(repair) 5 kg MAN no.: 09.15001-0105)

Propshaft joints and High-temperature grease

intermediate bearings, MAN 284 Li–H 2........................................ Lithium complex grease with
propshafts on eddy current mineral oil,
brakes, double-joint NLGI class 2,
propshafts, eccentric shaft drop point at least 230 °C
bearings on fan tensioner
Long-life lubrication: Brake
camshafts on rear axle, brake
shoe pins.
Lubricate steering knuckle.

Fifth wheel coupling................ Multipurpose grease MAN 285 Li–PF 2 .... Multipurpose grease (Lithium–12–
(if without central lubrication hydroxistearate type)
system or maintenance-free) + EP additives + MoS2,
Adjustment device .................. NLGI class 2,
Heavy-duty tractors (E-types) drop point at least 180 °C

Lifetime lubrication

Grease fill: Wheel hub .. Wheel bearing units................ High-temperature grease

Hub Units = maintenance- MAN 284 Li–H 2........................................ Lithium complex grease with
free; for repair only mineral oil,
(Factory fill MAN 284 Li–H 3) NLGI class 2,
drop point at least 230 °C

Initial fill service product in bold type. 53

SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

Lifetime lubrication ....... Operating temperature up
(continued) to 130 °C ............................... Multipurpose grease MAN 283 Li–P 2....... Multipurpose grease (Lithium–12–
Lubrication points hydroxistearate type)
+ EP additives, NLGI class 2,
drop point at least 180 °C

Without solid lubricants

(graphite, MoS2)

Operating temperature up
to 200 °C ............................... High-temperature lubricant TC 13–047 ..... None
Brake shoe pins, brake shoe
rollers, nozzle holders
(pressure screw contract
point), exhaust system (bolts)

Constant-velocity shafts......... Optimol Optitemp PU 035 ......................... Löbro TL 99.06.00.00.003

Wedge unit
(Simplex Expander) ............... High-temperature lubricating grease
Shell Darina 2............................................ None

54 Initial fill service product in bold type.

 SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

ANTI-CORROSION PROTECTION *

Destination indicators (interior), painted outside

surfaces ............................................................................. Paint-protecting wax M 3082–A ................ None
Framework / special-
section tubes (buses) ... Initial and subsequent
treatment ................................ Cavity wax M 3082–B2 ............................. None
Cab cavities (trucks) ..... Initial treatment....................... Cavity wax M 3082–B1 ............................. None
Subsequent treatment ............ Cavity wax M 3082–B3 ............................. None

Wheel arches, underfloor, cab underside, engine

compartment flap and front flap ...................................... Underfloor wax M 3082–C ........................ None
Alternatively:
Two-coat wax M 3082–Z........................... None
* Your MAN-Service workshop can provide details of approved products. These details are available on the MAN Intranet.
BATTERY

Filling.............................. Density 1.285 kg/l (32°Bé)...... Battery acid ............................................... None

Topping up ............................. Distilled water only .................................... None
Terminal protective cap ............................................... Techn. Vaseline S–743............................. None
TL 9150–0042
MISCELLANEOUS

Central lubrication
system............................ Vogel...................................... Multipurpose grease
(lubricating grease) Down to –25 °C MAN 283 LI–P 00/000............................... Multipurpose grease (Lithium–12–
hydroxistearate type)
+ EP additives, without solid
lubricants (graphite, MoS2)
NLGI class 00/000
In extremely cold
application conditions
(Vogel)............................. Down to –45 °C ...................... Gear oil Castrol Syntrans
SAE 75W–85W ......................................... None

Initial fill service product in bold type. 55

SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

MISCELLANEOUS
(continued)

Central lubrication
system ............................ Groeneveld
(lubricating grease) Down to –25 °C...................... Multipurpose grease MAN 283 LI–P 0 ...... Multipurpose grease (Lithium–12–
(continued) Alternatively: hydroxistearate type)
Down to –40 °C...................... Multipurpose grease + EP additives, without solid
MAN 283 LI–P 00/000 ............................... lubricants (graphite, MoS2)
NLGI class 0 or 00/000

BEKA–MAX........................... Multipurpose grease MAN 283 LI–P 2 ...... Multipurpose grease (Lithium–12–
hydroxistearate type)
+ EP additives, without solid
lubricants (graphite, MoS2)
NLGI class 2

In extremely cold
application conditions
(BEKA-MAX).................... Down to –50 °C...................... DEA Discor 8 EP 2 .................................... Lithium complex grease with
synthetic base oil,
NLGI class 2,
drop point at least 230 °C

Details of bio-degradable liquid greases are available on the Internet (see page 25).
Central lubrication
system ............................ Vogel...................................... High-pressure gear oil MAN 341 type N,
(oil) SAE 80W................................................... Gear oil MIL–L–2105
(API–GL 4)
or or
same engine oil as diesel engine .............. same engine oil as diesel engine

56 Initial fill service product in bold type.

 SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

MISCELLANEOUS
(continued)

Windscreen washers .... Down to –20 °C ...................... 40% by vol. denatured alcohol MAN 359 .. Isopropanol DIN 53245
60% by vol. water
3 g liquid cleaner (washing liquid) per litre

Below –20 °C.......................... 60% by vol. denatured alcohol MAN 359 .. Isopropanol DIN 53245
40% by vol. water
3 g liquid cleaner (washing liquid) per litre

Tyres and rims............... Assembly product and slip

additive ................................... Slip additive M 3224.................................. None

Hydrop shock absorber mount (Roland BAF) ............... Solid anti-fretting agent BW
Molykote BR 2, S 722 ............................... 8090 - 12 -172 - 4538 (300 ml
spray)
8030 - 12 - 150 - 9945 (1 kg)

Electric compressor...... (Large tank water tender) ....... Lubricating oil DIN 51506.......................... None
Group VD–L 100 (SAE 30) with TÜV test

AUXILIARY AIR-
CONDITIONING UNIT .... TGA ........................................ Antifreeze MAN 324 *) .............................. None
+ potable tap water
(mixed 50 : 50 by volume)

*) For products, see service products

database on the Internet

Initial fill service product in bold type. 57

SERVICE PRODUCTS / SPECIFICATIONS

Application and temperature range Item name / specification Alternative specification

AIR-CONDITIONING
SYSTEMS
with refrigerant R 134a .... Refrigerant oil for refrigeration
cycle and compressor
Buses and coaches
− Bock compressor ............... Fuchs DEA Reniso Triton SE 55
(ester oil) ................................................... see Bock list of lubricants
www@bock.de
− Konvekta compressor ........ Fuchs DEA Reniso Triton SE 55
(ester oil) ................................................... see www@bock.de
− York compressor................ Optimol SW 100 (ester oil) ........................ Fuchs DEA Reniso Triton SEZ 100
Trucks
− Unicla compressor ............. PAG–Oil Unidap 7 ..................................... None
− Zexel compressor .............. PAG–Oil Zexel ZXL 100 PG...................... Fuchs DEA Reniso PAG 46
− Sanden compressor
SD 7 H15 7982 .................. PAG–Oil Sanden SP 20 ............................ None
SD 7 H15 8117, 8157,
8162, 8164, 8171 ............... PAG–Oil Sanden SP 10 ............................ None
− Nippondenso compressor.. PAG–Oil ND 8 ........................................... None
− Kiki compressor ................. Fuchs DEA Reniso PAG 46
(0.25 litres MAN 09.11006–0004) ............. PAG–Oil Zexel ZXL 100 PG
Others
− NM 222 type 469 with
Göppel body....................... Fuchs DEA Reniso PAG 46
(0.25 litres: MAN 09.11006.0004) ............. PAG–Oil Zexel ZXL 100 PG
− EM/NM 223 type 469/A53
with Göppel body
Compressor SD 7 H15...... PAG–Oil Sanden SP 20 ............................ None
Compressor DKS 26......... PAG–Oil Zexel ZXL 100 PG...................... Fuchs DEA Reniso PAG 46
Compressor TM 31 ........... PAG–Oil Zexel ZXL 100 PG...................... Fuchs DEA Reniso PAG 46

NM 223.2 – type A66/76 with

Göppel body
Compressor TM 31 ................ PAG–Oil Zexel ZXL 100 PG...................... Fuchs DEA Reniso PAG 46

58 Initial fill service product in bold type.

 MAJOR COMPONENT FILL QUANTITIES

The fill quantity indicated is the approx. fill quantity in litres, The top-up quantity is the quantity between MIN and MAX on the
which is required when the fluid is changed. dipstick.

A slightly greater initial fill quantity is required when major Fill quantities not indicated below can be found in the model-
components are installed "dry". specific insert / annex included with the Operator's Manual.

The exact fill quantity is obtained by sticking to the fluid filling and Note: Differences are possible in the case of OEM engines,
fluid checking recommendations (see Maintenance Manual) special-purpose vehicles etc.; see the specific Operator's Manual.

From 09–2000: L2000 = LE–C, M2000L = LE–B,

M2000M = ME–B, F2000 = FE–A
DIESEL ENGINES

4-cylinder D 08..., with red dipstick ring 6-cylinder D 08..., with red dipstick ring
*) *)
Type Fill quantity Top-up quantity Type Fill quantity Top-up quantity
D 0824 FL 01, FLO...................... 11.5....................................... 2.0 D 0826 F, F 01, 02 ................................... 15.5...........................4.0
1)
D 0824 GF, GF 01 – 03............... 10.5....................................... 2.0 D 0826 FO 01, FR 01............................. 15.5 ...........................4.0
D 0824 LF 01 – 02....................... 14.5....................................... 4.0 D 0826 GF, GF 01 – 04 ........................... 15.5...........................4.0
D 0824 LFL 01 – 10 (L/M2000L) . 14.5....................................... 4.0 D 0826 GFA, GFA 01 – 04....................... 17.5...........................4.0
1)
D 0824 LOH 01, 02, 04, 05 ......... 14.5....................................... 4.0 D 0826 LF .............................................. 15.5 ...........................4.0
D 0826 LF 01 ........................................... 15.5...........................4.0
D 0834 LOH 01, 02 ..................... 14.5....................................... 4.0 D 0826
1)
LF 02, 03 ................................... 15.5 ...........................4.0
D 0834 LFG 01............................ 14.5....................................... 4.0 D 0826 LF 04 ........................................... 21.5...........................4.0
1)
D 0826 LF 05, 06, 07,.08 ....................... 15.5 ...........................4.0
D 0826 LF 10 ........................................... 15.5...........................4.0
4-cylinder D 08..., with green dipstick ring D 0826 LF 11, LF 13 (M 90)..................... 21.5...........................4.0
*)
D 0826 LF 15 – 18 (M2000L/M)............... 21.5...........................4.0
Type Fill quantity Top-up quantity D 0826 LF/217 ......................................... 15.5...........................4.0
D 0824 LF 02............................... 16.5....................................... 4.0 D 0826 LFG 01 – 08, 15, 16 .................... 17.5...........................4.0
D 0824 LFL 01 – 10 (L/M2000L) . 16.5....................................... 4.0 D 0826 LFL 01 (M2000L)......................... 21.5...........................4.0
D 0824 LFL ....(from Euro 2) ....... 17.5....................................... 4.0 D 0826 LFL 02, 03 (L2000)...................... 17.5...........................4.0
D 0826 LFL 03, 05 (M2000L)................... 21.5...........................4.0
D 0834 LFL 01, 03 (L/M2000L) ... 16.5....................................... 4.0 D 0826 LFL 06, 08 (L2000)...................... 17.5...........................4.0
D 0834 LFL 02 (L2000) ............... 16.5....................................... 4.0 D 0826 LFL 06, 07, 09 (M2000L)............. 21.5...........................4.0
D 0834 LFL 10, 11....................... 16.5....................................... 4.0
1)
D 0834 LFL ....(from Euro 2) ....... 17.5....................................... 4.0 With larger oil sump: 21.5

*) including full-flow oil filter. with superfine oil filter in bypass flow + 13 litres. Buses / coaches with additional reservoir + 10 litres. 59
 MAJOR COMPONENT FILL QUANTITIES

DIESEL ENGINES (continued) D08 . . – common-rail engines

6-cylinder D 08..., with red dipstick ring 4 or 6-cylinder D 08... – CR (Euro 3)

*)
Type Fill quantity Top-up quantity *)
1)
Type Fill quantity Top-up quantity
D 0826 LFL 09, 10 ..................................17.5 ..........................4.0
D 0834 LFL ..................................... 16.5....................................... 4.0
D 0826 LFL 10, 15, 17, 18 ........................21.5 ..........................4.0
D 0826 LOH 01–10, 12, 13, 15–19...........21.5 ..........................4.0 For engine output up to 240 hp (and for higher output if slopes above +/- 30%
D 0826 LUH 01 – 13 .................................21.5 ..........................4.0 are driven):
D 0826 OH 01 – 03...................................21.5 ..........................4.0 D 0836 LF/LFL................................ 21.5....................................... 4.0
For engine output above 240 hp (and if standard slopes up to +/- 30% are
D 0836 LF 01 – 05, 10 – 12 ......................21.5 ..........................4.0 driven):
D 0836 LFL 01 – 06 ..................................21.5 ..........................4.0 D 0836 LF/LFL................................ 27.5....................................... 5.0
2)
D 0836 LOH 02, 03 ................................21.5 ..........................4.0 D 0836 LOH/LUH............................ 27.5....................................... 5.0
D 0836 LUH 01, 02 ...................................27.5 ..........................4.0
1) 2) 1) 2) 1
With larger oil sump: 21.5, 27.5
GAS ENGINES
6-cylinder D 08... with green dipstick ring 6-cylinder CNG engines – E 28... with red dipstick ring
*)
Type Fill quantity Top-up quantity *)
Type Fill quantity Top-up quantity
D 0826 LFL 10, 18 ....................................21.5 ..........................5.0
E 2866 DF 01, 02, 03 .................. 33.0....................................... 6.0
1)
D 0836 LF 01– 05, LFL 01, 03, 04, 06......27.5 ..........................5.0 E 2866 DF 01 ........................... 42.0....................................... 6.0
E 2866 DOH 01........................... 33.0....................................... 6.0
6-cylinder D 08... from EURO 2 E 2866 DUH 01 ........................... 33.0....................................... 6.0
*)
E 2866 DUH 02, 03 ..................... 33.0....................................... 6.0
Type Fill quantity / dipstick Top-up quantity E 2866 LUH 01, 02...................... 33.0....................................... 6.0
Below 260 hp: E 2876 LUH 01, 02...................... 33.0....................................... 6.0
1)
D 0826/36 LF/LFL . . .... 21.5 / red or green .............................4 Larger oil sump with yoke
Above 260 hp:
D 0826/36 LF . . ......................... 21.5 / red ..........................4.0 6-cylinder LPG engines – G 28... with red dipstick
D 0826/36 LFL . . ..................... 27.5 / gree ..........................5.0
------------------------------------------------------------------------------------------------------------------------ *)
Type Fill quantity Top-up quantity
D 0826 LUH . . ...................... 21.5 / red ..........................4.0
D 0826/36 LOH . . ...................... 21.5 / red ..........................4.0 G 2866 DOH 01, 02, 03 .................. 33.0....................................... 6.0
D 0836 LUH . . .................. 27.5 / green ..........................5.0 G 2866 DUH 01 .............................. 33.0...................................... .6.0
D 0826 LFG . . ....................... 17.5 / red ..........................4.0 G 2866 DUH 02 .............................. 33.0....................................... 6.0
G 2866 DUH 03, 04, 05.. ................ 33.0....................................... 6.0

60 *) including full-flow oil filter. with superfine oil filter in bypass flow + 13 litres. Buses / coaches with additional reservoir + 10 litres.
 MAJOR COMPONENT FILL QUANTITIES

DIESEL ENGINES (continued) D20 . . / D 28 . . engines from EURO 2

D 2066 LF.., D 2865 / 66 / 76 / 40 / 42 LF.. / LOH.. / LUH.. / LFG..

Engine model Euro Oil sump Vehicle Green dipstick Red dipstick
Oil change Max. – Min. Oil change Max. – Min.
quantity*) quantity*)
D 2066 LF.. 3/4 Sheet- TGA 42 6 — —
(CR) metal
D 2840 LF.. 2/3 Sheet- F2000/ 48 6 33 6
(also CR) metal FE–A/TGA
D 2840 LF.. 2 Rear sump SX — — 33 6
D 2840 LF/LFG .. 2/3 Sheet- FX / HX 48 6 33 6
(also CR) metal
D 2842 LFG .. 2/3 Rear sump SX — — 36 6
(also CR)
D 2865 LF.. 2 Sheet- F2000 33 6 27 6
metal
D 2865 LUH .. 2 Underfloor Bus, — — 27 with additional 6
horizontal quantity + 10 l
D 2866/76 LFG .. 2/3 Rear sump SX — — 33 6
D 2866 LOH .. 2/3 Flat Bus, — — 33 with additional 6
(also CR) vertical quantity + 10 l
D 2866 LUH .. 2/3 Underfloor Bus, — — 33 with additional 6
horizontal quantity + 10 l
D 2866/76 LF.. 2/3 Sheet- F2000/ 42 6 33 6
(also CR) metal FE–A/TGA
FX / HX

*) including full-flow oil filter

61
 MAJOR COMPONENT FILL QUANTITIES

MANUAL GEARBOX
Type Fill quantity Type Fill quantity
ZF 6 S – 850 ................................................................................. 7.5 ZF 16 S – 222 with Intarder ..........................................................12.0
ZF 8 S – 180 ................................................................................. 9.0 with separately attached heat exchanger approx. + 2.0 litres
ZF 8 S – 180 with Intarder .......................................................... 12.0 ZF 16 S – 222 OD/DD ..................................................................10.5
ZF 9 S – 109 ................................................................................. 7.5 ZF 16 S – 222 OD/DD with Intarder .............................................12.0
ZF 9 S – 109 with Intarder / with secondary retarder.......... 12.0 / 9.0 ZF 16 S – 251 with Intarder ..........................................................13.5
ZF16 S – 109 ................................................................................. 8.5 ZF S 5 – 42 (installed vertical)........................................................3.5
ZF16 S – 109 with Intarder or secondary retarder ....................... 10.0 ZF S 6 – 36.....................................................................................7.0
ZF16 S – 150 ............................................................................... 11.0 ZF S 6 – 65 (installed horizontal / vertical) ...........................10.0 / 9.0
ZF16 S – 150 with secondary retarder......................................... 12.0 ZF S 6 – 65 + GV 80 ....................................................................12.0
ZF16 S – 151 ................................................................................. 8.0 ZF S 6 – 66 (installed horizontal / vertical) .............................8.5 / 5.5
ZF16 S – 151 OD/DD .................................................................... 9.0 ZF S 6 – 66 + GV 66 (installed horizontal / vertical).............10.5 / 8.0
ZF16 S – 151 OD/DD with Intarder.............................................. 11.0 ZF S 6 – 85...................................................................................10.5
with separately attached heat exchanger approx. + 2.0 litres ZF S 6 – 85 with secondary retarder ............................................14.0
ZF16 S – 160 A............................................................................ 19.0 ZF S 6 – 90...................................................................................12.0
ZF16 S – 181 ............................................................................... 10.5 ZF S 6 – 90 + GV 90 ....................................................................14.0
ZF16 S – 181 OD/DD .................................................................. 10.5 ZF S 6 – 1600 (installed horizontal / vertical) .......................8.5 / 13.0
ZF16 S – 181 OD/DD with Intarder.............................................. 12.0 ZF S 6 – 1600 with Intarder (installed horizontal / vertical) 14.5 / 16.0
ZF16 S – 181 with Intarder .......................................................... 12.0 ZF S 6 – 1900 / with Intarder ................................................8.5 / 19.0
ZF16 S – 190 ............................................................................... 15.0
NEW ZF–ECOSPLIT
ZF16 S – 190 A............................................................................ 19.0
The fill quantities indicated for the NEW ECOSPLIT are initial fill
ZF16 S – 220 ............................................................................... 13.5
with separately attached heat exchanger approx. + 2.0 litres quantities.
ZF16 S – 220 A............................................................................ 18.0 Oil change quantities are 1 – 2 litres less, depending on model
with separately attached heat exchanger approx. + 2.0 litres Type Fill quantity
ZF 16 S – 220 with secondary retarder........................................ 15.0
with separately attached heat exchanger approx. + 2.0 litres ZF 16 S – 1820 TO / 1823 TO .....................................................11.0
ZF 16 S – 221 .............................................................................. 10.5 ZF 16 S – 1821 TO with Intarder..................................................18.5
with separately attached heat exchanger approx. + 2.0 litres ZF 16 S – 1821 TO + NLP + Adapter for Intarder ........................19.5
ZF 16 S – 221 with Intarder ......................................................... 12.0 ZF 16 S – 1822 TO + NMV 221 ...................................................13.0
with separately attached heat exchanger approx. + 2.0 litres ZF 16 S – 1920 TD / 1923 TD .....................................................13.0
ZF 16 S – 221 OD/DD ................................................................. 10.5 ZF 16 S – 1921 TD with Intarder ..................................................21.5
ZF 16 S – 221 OD/DD with Intarder............................................. 12.0 ZF 16 S – 2220 TO / 2223 T ........................................................13.0
ZF 16 S – 251 .............................................................................. 11.5 ZF 16 S – 2221 TO with Intarder..................................................21.5
ZF 16 S – 222 .............................................................................. 10.5 ZF 16 S – 2221 TO + NLP + Adapter for Intarder ........................22.5
with separately attached heat exchanger approx. + 2.0 litres ZF 16 S – 2222 TO + NMV 221 ...................................................15.0
ZF 16 S – 2320 TO / 2323 TO......................................................13.0
ZF 16 S – 2321 TO with Intarder..................................................21.5
63
 MAJOR COMPONENT FILL QUANTITIES

NEW ZF–ECOSPLIT (continued) EATON SYNCHROMESH GEARBOX

The fill quantities indicated for the NEW ECOSPLIT are initial fill
The fill quantities indicated for Eaton gearboxes are initial fill
quantities.
quantities.
Oil change quantities are 1 – 2 litres less, depending on model
Oil change quantities depend on installation position – horizontal
Type Fill quantity
approx. 0.75 l less, vertical approx. 0.1 l less.
ZF 16 S – 2520 TO / 2523 TO .....................................................13.0
ZF 16 S – 2521 TO with Intarder..................................................21.5 Type Fill quantity
ZF 16 S – 2520 TO + 2SK ...........................................................21.5
ZF 16 S – 2521 TO + 2SK + Intarder ...........................................22.5 FS – 6109 A................................................................................... 8.5
ZF 16 S – 2521 TO + 2SK + NLP+ Adapter for Intarder ..............22.5 FS – 6309 A................................................................................... 8.5
ZF 16 S – 2521 TO + NLP + Adapter for Intarder ........................22.5 FS – 8209 A................................................................................... 8.5
ZF 16 S – 2522 TO + NMV 221 ...................................................15.0 FS – 8309 A................................................................................... 8.5
FS – 10209 .................................................................................. 10.0
TORQUE CONVERTER AND CLUTCH SYSTEM (WSK) FSO – 10209 ............................................................................... 10.0
installed separately FSO – 4106 B ................................................................................ 6.5
FSO – 5206 B ................................................................................ 6.5
Type Fill quantity
RTO 9513 .................................................................................. 13.0
WSK 400 ......................................................................................20.0 RTO 11613 .................................................................................. 13.0
WSK 400 with Retarder................................................................21.0 RTO 15613 .................................................................................. 13.0
WSK 440 (TC2)............................................................................18.0 RTS AutoShift (AS) 15613........................................................... 12.3
+ external oil cooler, depending on version up to....................+ 15.0 RTS AutoShift (AS) 17613........................................................... 12.3
the dipstick gives the most accurate measurement! RTSO 12316 A ............................................................................ 12.3
ZF – TRANSMATIC RTSO 12316 A with retarder preparation .................................... 14.0
Oil fill quantity without retarder
Type Fill quantity RTSO 17316 A ............................................................................ 12.3
WSK 400 + 16 S – 150.................................................................34.0 RTSO 17316 A with retarder preparation .................................... 14.0
WSK 400 + 16 S – 151.................................................................31.0 Oil fill quantity without retarder
WSK 400 + 16 S – 151 + Intarder ................................................32.0
WSK 400 + 16 S – 160 A .............................................................42.0 S.A.M.T. – B
WSK 400 + 16 S – 220.................................................................37.0 RTAO 12316 B ............................................................................ 12.3
WSK 400 + 16 S – 220 A .............................................................42.0 RTAO 12316 B with retarder preparation .................................... 14.0
WSK 400 + 16 S – 221.................................................................33.0 Oil fill quantity without retarder
WSK 400 + 16 S – 221 + Intarder ................................................34.0 RTAO 17316 B ............................................................................ 12.3
WSK 400 + 16 S – 222.................................................................33.0 RTAO 17316 B with retarder preparation .................................... 14.0
WSK 400 + 16 S – 222 + Intarder ................................................34.0 Oil fill quantity without retarder
WSK 440 + 16 S – 251.................................................................39,0
+ external oil cooler, depending on version.............................+ 15.0
+ Retarder .................................................................................+ 1.0
64
 MAJOR COMPONENT FILL QUANTITIES

EATON TWIN SPLITTER Type Fill quantity

The fill quantities indicated for Eaton gearboxes are initial fill ZF TC TRONIC 12 TC 2740 TO (H94, H95)................................12.0
quantities. with external oil cooler, depending on version up to .............. + 3.0
Oil change quantities depend on installation position – horizontal ZF 4/5/6 HP 500/502/590/600/602, 5 HP 592 ...................12.0 – 17.0
approx. 0.75 l less, vertical approx. 0.1 l less. ZF 6 HP 602 / with converter drain valve ...........................15.0 / 20.0
ZF 6 HP 902 (X45) ............................................................20.0 – 24.0
Type Fill quantity with external oil cooler, depending on version up to .............. + 5.0
the dipstick gives the most accurate measurement!
TSO – 11612 / 12612 / 12612 A .................................................. 13.5
STSO – 11612 (S.A.M.T.)............................................................ 13.5
TSO – 11612 / 12612 and 12612 A (S.A.M.T.)............................ 13.5 RETARDER
Type Fill quantity
AUTOMATIC / AUTOMATED GEARBOX
Voith 120–2 / with Modine heat exchanger (A20 buses)................4.0
Type Fill quantity Voith 130 / including heat exchanger .............................................8.5
Allison AT 545................................................................... 14.0 – 15.0 Voith 133 / including standard
Allison WT Typ MD–3560 P......................................................... 18.0 heat exchanger.............................................................................9.0
Eaton RTAO – 12316 A / 17316 A............................................... 12.3 with special heat exchanger (truck 1)......................................10.5
Voith Diwa 506............................................................................. 21.0 Voith R115 / including heat exchanger...........................................5.4
Voith Diwa D 851 to D 864.3 E ......................................... 21.0 – 23.0
the dipstick gives the most accurate measurement
Voith Midimat BR ........................................................................... 7.0 POWER TAKE-OFFS
gearbox only, see "Retarder" for flange-mounted retarder 120 Type Fill quantity (in addition to main gearbox)
Renk Doromat 873A .................................................................... 15.0
Renk Doromat 874A/AM/BM ....................................................... 20.0 Eaton Eaton power take-off............................................................0.3
Renk REMAT Eaton – Hydrocar – power take-off
HS 225/226/227 (with transfer case) ......................................... 65.0 1800 Series, 2200 Series,
WR 0.97/1.03/1.075 – PS 225.32, 226.32 2801 Series ..................................................................................0.3
(shared oil circuit) .................................................................... 50.0 2802 Series ..................................................................................0.5
2900 Series, 2903 Series, 2905 Series........................................1.0
Type Fill quantity 2400 Series, 2830 Series .............................................................1.5
ZF N 110, N 130.............................................................................1.5
ZF ASTRONIC 12 AS 2301 (MAN TipMatic) (TGA) .................... 11.0 ZF N 109, N 112, N 220 .................................................................0.5
with Intarder (TGA) .................................................................. 12.0 ZF N 151, N 221.............................................................................1.0
ZF ASTRONIC 12 AS 3001 (MAN TipMatic) (TGA) .................... 12.0 ZF NMV 110, 130, 130E..... ...........................................................2.0
with Intarder (TGA) .................................................................. 13.0 ZF NMV 221..... .............................................................................2.0
ZF ASTRONIC 12 AS 2301 B (MAN TipMatic) (R02/R03).......... 11.0
with Intarder (R02/R03) ........................................................... 12.0

65
 MAJOR COMPONENT FILL QUANTITIES

TRANSFER CASE HYDROSTATIC FAN DRIVE

The fill quantity indicated is for the dry transfer case. When
changing the oil, the fill quantity is 1.0 to 1.5 l less, depending on Type / version Fill quantity
type. External gearbox oil cooler
Type Initial fill quantity Forward-control vehicle F 8................................................... 15.0
Forward-control vehicle F 90................................................. 15.0
G .... – with permanent front-axle drive Expansion tank made from sheet steel
G 1000–2 .......................................................................................4.7 Forward-control vehicle F 90................................................. 30.0
G 1700–1 .......................................................................................6.3 Expansion tank made from aluminium
G 1700–2 .......................................................................................6.3
G 2500–2 .......................................................................................7.2 Radiator:
G .... – with non-permanently engaged front-axle drive Coaches SR 240 / 280 / 321 / 361
G 1000–2 .......................................................................................5.0 Behr T 16/20° .......................................................................... 8.0
G 1700–1 .......................................................................................7.5 Behr T 12/25° .......................................................................... 6.0
G 1700–2 .......................................................................................7.5
G 2500–2 .......................................................................................8.0 Buses and coaches
VG 750 (ADM) FRH (A02 / A03 / A13), SG (793), ÜL (893), SÜ (888),
with interaxle differential.............................................................5.5 ÜL (A01/ A04), NÜ (A20)............................................ 20.0 – 22.0
without interaxle differential........................................................6.4 RH (R02/R03)............................................................. 20.0 – 22.0
NL/NG (A10 / A11 / A15 / A18) .................................. 20.0 – 22.0
VG 1600 flange-mounted on 6 HP 902 with permanent front-axle drive NM 222 (469 with Göppel body)................................. 20.0 – 22.0
without lubricating pump.............................................................6.6 NM 223.3 F, NM 283,3 F (A35 with Göppel body) ... 19.25 – 20.0
with lubricating pump and power take-off...................................7.7 Note dipstick marking!
G 102 Bus and coach chassis'
with permanent front-axle drive ..................................................5.2 10./11.150/180/190/220/230 HOCL (469) ............................. 13.0
with non-permanently engaged front-axle drive .........................5.5 13.230 HOCL (A53)............................................................... 22.0
G 172 / G 173 16./18./22./24.360/370/422 HOCL(N) ................................... 13.0
with permanent front-axle drive ..................................................5.8 18.370/420 HOCL (A51)............................................. 20.0 – 22.0
with non-permanently engaged front-axle drive .........................7.0 previously .......................................................................... 13.0
G 252 / G 253 Forward-control underfloor F 90 ....................................... 20.0 – 22.0
with permanent front-axle drive ..................................................7.2 Note dipstick marking!
with non-permanently engaged front-axle drive .........................8.0 Heavy-duty van (U 07) ................................................................. 20.0

66
 MAJOR COMPONENT FILL QUANTITIES

AIR-CONDITIONING SYSTEM (refrigerant) AUXILIARY AIR-CONDITIONING UNIT (antifreeze / drinking

water)
Vehicle type Approx. fill quantity
Forward-control L/M2000, LE–C, ME–C/B, F2000, FE–A Vehicle model Approx. fill quantity
with round-tube condenser............................................... 1.15 kg TGA (mixing ratio 50 : 50) ...................................................... 22 litres
with flat-tube condenser ................................................... 0.95 kg
TGA / with auxiliary air-conditioning unit.....................0.90 kg / 1.2 kg
Buses and coaches ANTI-JACKKNIFE SYSTEM
− A01/A04 (Webasto Thermal) .............................................. 10.0 kg Bus / coach type Fill quantity
− A01/A04 (Webasto Thermal + driver's area) ...................... 11.0 kg
Articulated buses type A11 / A18 / A19 (SKD 540) ........................4.0
− A02 (Webasto) .................................................................... 10.0 kg
Articulated buses type A23 / A24 (SKD 420) ...............................3.65
− A02/A03 (Webasto + driver's area)..................................... 11.0 kg
− A10 / A15 (Konvekta).......................................................... 10.0 kg LIFTING AXLE: Hydraulic
− A10 / A15 (Webasto).................................................... 8.5 – 9.5 kg
− A10 / A15 (Konvekta + driver's area) .................................. 10.5 kg Vehicle type Fill quantity
− A11 / A18 (Webasto)........................................................... 18.0 kg Forward-control F 90 (type E12, 75, 95).........................................6.0
− A11 / A18 (Sütrak driver's area only) .................................... 4.2 kg Shock absorber oil: Aral Vitamol 1010
− A13–MANAS....................................................................... 13.5 kg
− A20 / A21 (Webasto / Konvekta Thermal) ............................ 9.5 kg LEADING, TRAILING AND REAR AXLE:
− A20 / A21 (Webasto / Konvekta Thermal + driver's area) .. 10.5 kg With hydraulic steering
− A20 / A21/ A23 / A37 (Webasto CC4ES driver's area) ......... 1.1 kg (fill quantities vary depending on line lengths / equipment)
− A21 (Webasto + driver's area) ............................................ 10.5 kg System Fill quantity
− A23 (Webasto / Konvekta Thermal).................................... 13.5 kg ®
ZF–Servocom RAS (T06, T35, T36, T37, A54) ...........................6.0
− A23 (Webasto / Konvekta Thermal + driver's area)............ 14.5 kg ®
ZF–Servocom RAS EC1 (E65, E73, A25/26/30) ..........................2.9
− A25 / A26 (Webasto / Konvekta Thermal) .......................... 10.0 kg ®
ZF Servocom RAS EC3 (E72, E74, E77, E78, E79) ...................2.9
− A25 / A26 (Webasto / Konvekta Thermal + driver's area) .. 11.0 kg ZF–Servocom HS (= Hydrostatic Steering, E47, E53, E63, E67) ..6.0
− A27 (Sütrak) / A28 (Sütrak).......................................9.8 kg / 9.0 kg ®
ZF–Servocom RAS (H17 to H21) .................................................4.5
− A72 SÜ–MAN Türkiye (Webasto–Aerosphäre)................... 10.5 kg ®
ZF–Servocom RAS EC1 (H23, H24, H94) ...................................4.0
− A72 SÜ–MAN Türkiye (Konvekta ACX 622/624) ................ 10.0 kg ®
ZF–Servocom RAS EC1 (H95)..............via vehicle central hydraulic
− NM 222 – type 469 Göppel body .......................................... 4.5 kg system 70.0 litres in total
− EM/NM 223 – type 469/A53 Göppel body............................. 5.0 kg
− NM 223.2 – type A76 Göppel body ....................................... 5.0 kg FRONT AXLE: With hydraulic steering
− R07W/R08W, R07T/R08T (Konvekta ACX633/635/637) ... 11.0 kg (fill quantities vary depending on line lengths / equipment)
− R07W/R08W, R07T/R08T (Aurora EOS AC 400) ..... 9.5 – 10.0 kg Steering if steering front axle fitted TGA
− R07W/R08W, R07T/R08T (Webasto Top 2000) ................ 11.0 kg ZF–Servocom, RBL power steering.........................................3.5

67
MAJOR COMPONENT FILL QUANTITIES

FRONT AXLES
Fill quantity:
Axle type Total Centre drive Planetary drive Steering knuckle
(through-drive)
V 7/9 – 90 L ............................................... 5.2 —— 2 x 2.5 Per side 2 x 0.05
VA 7 – 0750 – G.. ...................................... 8.2 5.0 2 x 1.5 Per side 2 x 0.05
VA 7 – 0950 – M5/M6/M7/M12.................. 8.2 5.0 2 x 1.5 Per side 2 x 0.05
VA 7 – 0950 – M8/M9/M10/M11................ 9.7 5.5 2 x 1.5 Per side 2 x 0.05
VA 7 – 1050 – G5/G7/G10/G11/G19/G21 8.2 5.0 2 x 1.5 Per side 2 x 0.05
VA 7 – 1050 – G8/G9 8.7 5.5 2 x 1.5 Per side 2 x 0.05
VA 9 – 0540............................................... 8.2 6.5 2 x 0.75 Per side 2 x 0.05
VA 9 – 0950 / 1050.................................... 9.2 6.0 2 x 1.5 Per side 2 x 0.05
VA 9 – 1050 – S 3 + 2.9 m width ............... 10.4 7.2 2 x 1.5 Per side 2 x 0.05
VAD 7 – 0750 – M ..................................... 10.2 5.0 (+ 2.0) 2 x 1.5 Per side 2 x 0.05
VAD 7 – 0950 – M5/M6 ............................. 14.7 9.5 (+ 2.0) 2 x 1.5 Per side 2 x 0.05
VAD 7 – 0950 – M8/M10 ........................... 16.2 11.0 (+ 2.0) 2 x 1.5 Per side 2 x 0.05
VAD 7 – 1050 – G5/G6.............................. 14.7 9.5 (+ 2.0) 2 x 1.5 Per side 2 x 0.05
VAD 7 – 1050 – G8/G10............................ 16.2 11.0 (+ 2.0) 2 x 1.5 Per side 2 x 0.05
VAD 9 – 0950 ............................................ 10.7 5.0 (+ 2.5) 2 x 1.5 Per side 2 x 0.05
VP 09......................................................... 9.4 6.0 2 x 1.5 Per side 2 x 0.05
VPD 09 ...................................................... 12.2 6.5 (+ 2.5) 2 x 1.5 Per side 2 x 0.05

68
 MAJOR COMPONENT FILL QUANTITIES

TRAILING AXLES, steered

Fill quantity:
Axle type Total Centre drive Planetary drive Steering knuckle
HAA – 0950 L............................................ 8.2 5.0 2 x 1.5 Per side 2 x 0.05
HN 9–90 L (emptied)................................. 0.2 empty empty Per side 2 x 0.05

CENTRE AXLES
Fill quantity:
Bus / coach type Axle type Total Wheel bearings Remarks
MANAS (Turkey) ....................................... HOM 9 – 1300 4.0 2 x 2.0
NG 272 (type A11) .................................... HONG –1100 9.0 2 x 4.5 Previous version
NG 272 (type A11) .................................... HONG –1100 4.0 2 x 2.0 Current version,
conical wheel hub
caps
SG 242/292 (Pusher) ................................ HOM 7 – 1100 9.0 2 x 4.5 Previous version
SG 322 ...................................................... HOM 7 – 1100 4.0 2 x 2.0 Current version,
conical wheel hub
caps
NG (type A23/A24) .................................... HONP–1300 500 g 2 x 250g Grease fill (old)
NG (type A23/A24) .................................... HONP–1300–01 500 g Hub Unit 2 x 120 g (100g**) (new)
** if central lubrication system is used

SPRING BEARINGS
Heavy-duty tandem axles Fill quantity:
Forward-control F90 / F2000 / M2000M / bonneted vehicles........... 2 x 1.1

69
 MAJOR COMPONENT FILL QUANTITIES

REAR AXLES
Fill quantity:
) )
Axle type Total Centre drive* Through-drive* Planetary drive
H 7 – 0870 ................................................. 12.5 8.5 —— 2 x 2.0
H 7 – 0880 M/G (normal width) ................. 12.0 9.0 —— 2 x 1.5
H 7 – 0880 M/G (extra width) .................... 13.7 10.7 —— 2 x 1.5
H 7 – 1080/1180/1380 (M)
10 wheel studs ....................................... 16.0 (14.0) 9.0 —— 2 x 3.5 (2 x 2.5)
H 7 – 13120 – M (normal width) ................ 15. 8 12.8 —— 2 x 1.5
H 7 – 13120 – M (extra width) ................... 17.0 14.0 —— 2 x 1.5
H 9 – 0670 ................................................. 10.0 8.5 —— 2 x 0.75
H 9 – 0970 ................................................. 12.5 8.5 —— 2 x 2.0
H 9 – 1180/1380 ........................................ 16.0 9.0 —— 2 x 3.5
H 9 – 13120 (Trilex wheel spider) / 2.9 m.. 18.0 / 19.0 13.0 / 14.0 —— 2 x 2.5
H 9 – 13120/16120 .................................... 20.0 13.0 —— 2 x 3.5
H 9 – 1380 (Trilex wheel spider)................ 14.0 9.0 —— 2 x 2.5
HD 7 – 0880 M/G (normal width)............... 14.0 9.0 2.0 2 x 1.5
HD 7 – 0880 M/G (extra width).................. 15.7 10.7 2.0 2 x 1.5
HD 7 – 0880 S ........................................... 16.0 11.0 2.0 2 x 1.5
HD 7 – 10120/13120/16120 ...................... 22.0 13.0 2.0 2 x 3.5
HD 7 – 1080/1180/1380 (M) ...................... 18.5 (16.5) 9.5 2.0 2 x 3.5 (2 x 2.5)
HD 7 – 13120 – M (normal width).............. 21.5 16.5 2.0 2 x 1.5
HD 7 – 13120 – M (extra width)................. 22.8 17.8 2.0 2 x 1.5
HD 9 – 1180/1380 ..................................... 20.0 11.0 2.0 2 x 3.5
HD 9 – 13120/16120 ................................. 23.0 14.0 2.0 2 x 3.5
HD 9 – 1380 (Trilex wheel spider) ............. 18.0 11.0 2.0 2 x 2.5
HD 9 –13120 2.9 m ................................... 24.0 15.0 2.0 2 x 3.5
* centre drive and through-drive share the same oil circuit

70
 MAJOR COMPONENT FILL QUANTITIES

REAR AXLES (continued)

Fill quantity:
) )
Axle type Total Centre drive* Through-drive* Planetary drive
HO 7 – 11120............................................ 20.0 13.0 —— 2 x 3.5
HO 7 – 1180 (Trilex wheel spider) ............ 14.0 9.0 —— 2 x 2.5
HO 7 – 1180/1380..................................... 16.0 9.0 —— 2 x 3.5
HO 7 – 1180/1380..................................... 16.0 9.0 —— 2 x 3.5
HO 9 – 11120............................................ 18.5 11.5 —— 2 x 3.5
HO 9 – 11120 / 13120............................... 20.0 13.0 —— 2 x 3.5
HO 9 – 1180 / 1380................................... 16.0 9.0 —— 2 x 3.5
HONL – 1180 ............................................ 19.0 12.0 —— 2 x 3.5
HONP – 13100.......................................... 18.0 Wheel hub grease fill 2 x 250 g (old)
HONP – 13100 – 01.................................. 18.0 Hub Unit 2 x 120 g (100g**) (new)
HP – 1333 ................................................. 12.7 8.5 —— 2 x 2.1
HP – 1352 ................................................. 16.2 12.0 —— 2 x 2.1
HPD – 1353............................................... 14.7 10.5 —— 2 x 2.1
HPD – 1382............................................... 17.7 13.5 —— 2 x 2.1
HU – 1330 (A35) ....................................... 22.0 Wheel hub grease fill 2 x 120 g (100g**)
* Centre drive and through-drive share the same oil circuit
** If central lubrication system is used

71
 MAJOR COMPONENT FILL QUANTITIES

REAR AXLES / HYPOID AXLES

Fill quantity:
Axle type Total Centre drive Wheel hub
HYD – 1175 ............................................... 15.4 14.0 2 x 0.7
HYD – 1370 14.5 14.5 2 x 120 g (100 g**)
HOY – 0955 ............................................... 11.4 10.0 2 x 0.7
HOY – 1175 ............................................... 16.4 15.0 2 x 0.7
HOY – 0855 12.8 12.8 2 x 0.5
HY – 0645.................................................. 4.6 4.0 2 x 0.3
HY – 0720.................................................. 5.6 5.6 ——
HY – 0855.................................................. 12.8 11.8 2 x 0.5
HY – 0925.................................................. 10.0 10.0 ——
HY – 0955.................................................. 11.4 10.0 2 x 0.7
HY – 1130.................................................. 10.0 10.0 2 x 100 g (80 g**)
HY – 1133.................................................. 10.0 10.0 2 x 120 g (100 g**)
HY – 1175.................................................. 12.9 11.5 2 x 0.7
HY – 13110................................................ 15.7 14.3 2 x 0.7
HY – 1336–B ............................................. 15.0 15.0 2 x 120 g (100 g**)
HY – 1350.................................................. 14.5 14.5 2 x 120 g (100 g**)
** If central lubrication system is used

72
 INDEX

Page Page
Additives, diesel fuel ...................................................................... 30 Batteries .........................................................................................55
Additives, engine oil........................................................................ 26 Bio-diesel (FAME), engine oil change intervals...............................30
Air-conditioning system: Refrigerant oil .......................................... 58 Buses / coaches and bus / coach chassis FOC / HOC:
Allison gearboxes .................................................................... 44 / 65 Engine oil change intervals .......................................................24
Allocation into maintenance groups................................................ 13
Allocation of maintenance groups................................................... 13
Analysis values (water quality)........................................................ 36 Cab tilt hydraulics ...........................................................................49
Anti-corrosion agent (notes) ........................................................... 35 Cable winch and crane....................................................................51
Anti-corrosion protection: Preservation, cavities ............................ 55 Cable winch gearbox (Rotzler) ........................................................44
Anti-jackknife system ...................................................................... 51 Catalytic converter with particulate matter filter (Euro 4).................27
Antifreeze........................................................................................ 35 Central hydraulic system (heavy-duty tractors) ...............................50
Antifreeze (mixing table) ................................................................. 35 Central hydraulic system (LX / SX)..................................................50
Antifreeze / anti-corrosion protection: Disposal .............................. 36 Central hydraulic system (production vehicles)...............................50
Application conditions for rail vehicles ..................................... 13 / 24 Central lubrication system .......................................................55 – 56
Application: Gear oils...................................................................... 37 Change intervals, engine oil: Buses / coaches and
Approved service product quality.................................................... 25 bus / coach chassis FOC / HOC...............................................24
AS–Tronic gearboxes .............................................................. 65 / 42 Change intervals, engine oil: Trucks ...............................................23
ATF (Automatic Transmission Fluid) .............................................. 38 Change intervals, rail vehicles.........................................................24
Automated manual gearbox, TipMatic (ZF–Astronic) ..................... 42 Clutch actuator ................................................................................50
Automatic gearbox.................................................................. 42 – 44 CNG and LPG engine oils ...............................................................28
Automatic transmission fluid (ATF) ................................................ 39 CNG engine oil change intervals......................................23 – 24 / 28
Auxiliary air-conditioning unit ................................................... 57 / 67 CNG fuel..........................................................................................32
Aviation turbine fuel (kerosene) ...................................................... 34 Coolant ............................................................................................35

73
 INDEX

Page Page
Crane and cable winch....................................................................51 Eaton synchromesh gearbox ......................................................... 37
CRT filters .......................................................................................26 Engine cleaning .............................................................................. 38
Engine oil additives......................................................................... 26
Engine oil application (exceptions) ................................................. 27
D 08–Euro 2, 3 – diesel engines: Engine oil fill quantities..............60 Engine oil change intervals (CNG / LPG) ....................................... 28
D 28–Euro 2, 3 – diesel engines: Engine oil fill quantities ..............61 Engine oil change intervals, bio-diesel ........................................... 30
Dangerous materials classes to VbF ..............................................30 Engine oil change intervals, buses / coaches and
Diesel engines bus / coach chassis FOC / HOC .............................................. 24
Cooling......................................................................................39 Engine oil change intervals, FAME................................................. 30
Engine oils ................................................................................26 Engine oil change intervals, rail vehicles ........................................ 24
Fuel...........................................................................................39 Engine oil change intervals, trucks ................................................. 23
Initial fill .....................................................................................39 Engine oil change intervals: FAME................................................. 30
Lubrication ................................................................................39 Engine oil fill volumes from D08 Euro 2 diesel engines.................. 60
Service fill .................................................................................39 Engine oil fill volumes from D28 Euro 2 diesel engines.................. 61
Diesel engines with catalytic converter with particulate Engine oil for CNG and LPG engines ............................................. 28
matter filter (Euro 4)..................................................................27 Engine oil, miscibility....................................................................... 26
Diesel engines with particulate trap (CRT system) .........................27 Engine oils (products) ............................................................. 59 – 71
Diesel fuel .......................................................................................29 Engine oils for diesel engines (notes)............................................. 26
Additives ...................................................................................30 Euro 0, 1, 2, 3 – diesel engines (important note)............................ 26
Low-sulphur / sulphur-free ........................................................29 Exceptions (engine oil application) ................................................. 27
Sulphur content.........................................................................27 Extreme application conditions ......................................................... 4
Disposal: Antifreeze / anti-corrosion protection...............................36
Driven axles ....................................................................................47

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FAME (biodiesel), engine oil change intervals ............................... 30 Implement hydraulics (SX 90 SX 2000) ..........................................50
Fuel: Diesel engines ....................................................................... 39 Initial fill: Diesel engines ..................................................................39
Fuel: Gas engines........................................................................... 40 Intarder, ZF...............................................................................40 / 46
Fungal growth in fuel system .......................................................... 31 Internet addresses...................................... Inside of cover sheet / 25

Gas engines Kerosene (aviation turbine fuel)......................................................34

Cooling ..................................................................................... 40 Kongsberg gearchange system, TGA .............................................50
Fuel .......................................................................................... 40
Lubrication................................................................................ 40
Gear oils – application .................................................................... 37 Leading axle steering RAS ® .........................................................49
Gear oils – change intervals ........................................................... 37 Letter of approval (service products)...............................................25
Gearbox .......................................................................................... 40 Lifetime lubrication ..................................................................53 – 54
Grease fill: Wheel hub, Hub Units................................................... 53 Lifting axle, hydraulic .......................................................................51
Greasing points....................................................................... 52 – 54 Liquid gas (LPG) .............................................................................33
Low-sulphur diesel fuel....................................................................29
LPG and CNG engine oils ...............................................................28
Hub Units, grease fill: Wheel hub............................................ 53 / 85 LPG fuel ..........................................................................................33
Hydraulic systems................................................................... 49 – 51 LPG: Engine oil change intervals ....................................................28
Hydrop shock absorber mount (Roland BAF)................................. 57 Lubrication: Diesel engines .............................................................39
Hypoid axles ................................................................................... 47 Lubrication: Gas engines.................................................................40

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Maintenance group A .............................................................16 – 17 Outside cleaning – major components / vehicle ............................ 38
Maintenance group A+ ....................................................................15
Maintenance group B ..............................................................18 – 19
Maintenance group C..............................................................20 – 21 Particulate trap (CRT system)........................................................ 26
Maintenance groups – allocation ....................................................13 Periodic lubrication ................................................................. 52 – 53
Maintenance record ........................................................................13 Petroleum mix (winter operation) .................................................... 29
Maintenance system "ProFit-Check II", TGA ..........................11 – 12 Pritarder (water retarder) ......................................................... 35 / 46
Maintenance system "ProFit-Check II", ProFit-Check II TGA ............................................................... 11 – 12
trucks and buses / coaches ........................................................9 ProFit-Check II (time-based maintenance system),
Maintenance system based on maintenance groups......................13
trucks and buses / coaches........................................................ 9
Maintenance systems, applicability .............................................3 – 4
Major components, cleaning outside...............................................38
MAN–TipMatic (ZF–Astronic)..........................................................42
Manual gearbox ......................................................................40 – 41
Rail vehicles (light rail cars) – note ......................................... 13 / 24
Methane number (CNG)..................................................................32 Rail vehicles: Engine oil change intervals....................................... 24

Micro-organisms in fuel system, remedy.........................................31 Rape seed oil methylester (RME)................................................... 30

Micro-organisms in the fuel system.................................................31 Rape seed oil methylester: Engine oil change intervals ................. 30

Miscibility of engine oils...................................................................26 Rear axle steering RAS ®............................................................... 49

Mixing table (antifreeze)..................................................................35 Rear axles....................................................................................... 47

Multigrade engine oils (notes) .........................................................26 Renk REMAT gearbox.................................................................... 44

Retarder.......................................................................................... 46
Rims and tyres................................................................................ 57
RME (rape seed oil methylester) .................................................... 30
Natural gas (CNG)..................................................................32 – 33

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SAE classes Time-based maintenance system "ProFit-Check II",

Engine oil.................................................................................. 27 trucks and buses / coaches ........................................................9

Gear oils ................................................................................... 37 TipMatic (ZF–Astronic) ....................................................................42

Secondary retarder, ZF............................................................ 40 / 46 Tipper hydraulics .............................................................................51

Service fill: Diesel engines.............................................................. 39 Trailing axle steering (RAS, HS) .....................................................49

Service products / specifications .................................................... 39 Trailing axle steering RAS ® ...........................................................49

Service products, service product quality, approval ....................... 25 Trailing axle, driven .........................................................................47

Shock absorber mount, Hydrop (Roland BAF) ............................... 57 Transfer case ..........................................................................44 – 45

Single-grade engine oils (notes on use) ......................................... 26 Trucks: Engine oil change intervals.................................................23

Sludge in fuel system...................................................................... 31 Tyres and rims.................................................................................57

Specifications / service products ............................................ 39 – 58

Spring bearings............................................................................... 48
Steering gear .................................................................................. 45 Unit fill quantities
Sulphur content in diesel fuel.......................................................... 27 Air-conditioning system.............................................................67
Sulphur-free diesel fuel................................................................... 29 Automated gearboxes...............................................................65
Suspension, hydraulic..................................................................... 51 Automatic gearboxes ................................................................65
Synchromesh gearbox, Eaton ................................................. 37 / 40 Auxiliary air-conditioning unit ....................................................67
Synchromesh gearbox, ZF ...................................................... 37 / 40 Centre axles..............................................................................69
DKS anti-jackknife system ........................................................67
Engine...............................................................................59 – 61

TC–Tronic gearboxes.............................................................. 65 / 42 Front axles ................................................................................68

Hydrostatic fan drive .................................................................66
Telma retarder ................................................................................ 46
Hypoid axles..............................................................................72
Time-based maintenance system "ProFit-Check II", TGA...... 11 – 12

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Lifting axle, hydraulic ................................................................67 Water retarder (Pritarder) ........................................................ 35 / 46
Manual gearboxes ............................................................63 – 65 Wheel hub: Grease fill .................................................................... 48
New Ecosplit ......................................................................63 / 64 Wheel hub: Oil fill............................................................................ 48
Power take-offs.........................................................................65 Windscreen washers ...................................................................... 57
Rear axles.........................................................................70 – 72 Winter diesel fuel ............................................................................ 29
Retarders ..................................................................................65 Winter diesel quality........................................................................ 29
Spring bearings.........................................................................69 Winter operation ............................................................................. 29
Trailing axle, driven, steering....................................................69
Trailing axle, with hydraulic steering (RAS ®, HS) ..................67
Transfer cases ..........................................................................66 ZF–AS–Tronic (MAN–TipMatic) ..................................................... 42
WSK (torque converter and clutch system) ..............................64 ZF–Duo Drive HZA (hydrostat) ....................................................... 41
ZF Transmatic...........................................................................64 ZF–Ecomat ..................................................................................... 43
ZF–Intarder .............................................................................. 40 / 46
ZF–TC–Tronic gearboxes............................................................... 43
Vehicle / major components – outside cleaning .............................38 ZF–Transmatic................................................................................ 43
Viscosity regulations ZF secondary retarder ............................................................. 40 / 46
Engine oil ..................................................................................27 ZF synchromesh gearbox ........................................................ 40 / 46
Gear oils ...................................................................................37 ZF torque converter and clutch system (WSK)............................... 43
Voith Diwa gearbox .................................................................42 – 43

Warranty.........................................................................................25
Water quality ...................................................................................36

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Wartungs– und Betriebsstoffempfehlungen "07–2004"

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