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‐ MAN diagnostic code 5 05533-10 / 05533 (“GDK/PDF 5533”) on a TGX 480 denotes an SCR-AdBlue malfunction: “return-flow too low / blocked or no dosing return”.
‐ Root causes: crystallised or frozen AdBlue, clogged return hose or injector, faulty dosing-pump module (including its internal purge valve), restricted filter, damaged wiring or failed heating.
‐ Vehicle consequences: “Malfunction emission control” lamp, power derate and, if ignored, possible legally enforced speed limitation or no-start.
Functional background
• Euro 5/6 MAN TGX uses a Bosch-based SCR system (“GDK/PDF”) that pressurises AdBlue (DEF: 32.5 % urea) to ≈4–6 bar, sprays it upstream of the SCR catalyst, then automatically purges/returns surplus fluid to prevent crystallisation.
• Code 05533 is triggered when the aftertreatment ECU measures insufficient flow or pressure decay during the purge cycle:
– Δp across internal flow sensor wrong
– Return-line temperature/pressure outside window
– Pump current too high (blocked) or too low (run-dry).
Typical physical faults
• Crystallisation in injector or return hose (white urea deposits)
• Blocked pump filter (integrated 50 µm cartridge)
• Kinked / pinched hose after tank or chassis repairs
• Frozen fluid if tank and line heaters, PTC harness or temperature sensor failed (< -11 °C)
• Dosing module internal check/relief valve stuck
• Contaminated or out-of-spec AdBlue (iso 22241 < 31 % or > 34 % urea).
Electrical / control faults
• 24 V feed, ground, LIN/CAN to DCU loose or corroded
• Pump-current feedback wire open, giving false “no flow”
• ECU SW older than 2021-09 MAN update (improved blockage detection).
Diagnostic workflow (MAN-cats III, Jaltest, TEXA…)
a) Read freeze-frame → confirm 5 05533-10 (FMI 10 “rate deviates / flow low”). Note other codes (e.g. 03792-xx NOx, 04829 heating).
b) Static checks
– AdBlue level, colour, smell; max 12 months old.
– Crystals on filler cap, injector or hose joints.
c) Return-flow / purge test (special function “System purge”)
– Measure ≥250 ml in 60 s at 20 °C. < 150 ml ⇒ blockage.
d) Pressure test
– Build-up 5 bar in < 10 s, decay to 0 bar in < 3 s when pump off. Slow decay ⇒ restriction or stuck valve.
e) Electrical tests
– Pump supply 24 ± 1 V under load, < 8 A.
– Heater resistance 2–6 Ω @ 25 °C.
f) Line inspection
– Disconnect return line at tank and blow low-pressure air; any back-pressure indicates blockage.
g) Filter inspection
– Replace cartridge (every 200 000 km or yearly).
Decision tree
• Crystals/contamination only → flush with warmed de-ionised water, replace filter, clear codes.
• Hose damaged → replace hose (use ISO 22241-3 compatible PA12).
• Pump not achieving pressure or fails flow test → replace dosing-pump module (sealed unit).
• Electrical fault → repair wiring, reseal connectors with dielectric grease.
‐ 2023–24 MAN service bulletins recommend software v2.4 or newer for improved “return flow plausibility” logic and reduced nuisance trips.
‐ New TGX generation adopts integrated heated stainless lines to combat winter blockages.
‐ Remote diagnostics via RIO / MAN DigitalServices now push SCR fault data to the fleet portal, allowing proactive maintenance.
‐ Aftermarket offers NOx-sensor delete kits; use is illegal in the EU/UK and voids warranty.
‐ Return-flow ensures lines empty when engine stops; otherwise urea crystallises (biuret) at > 80 °C or when water evaporates.
‐ A 4 % flow reduction for > 30 s triggers FMI 10; ECU repeats test each key-cycle.
‐ Analogy: Think of the pump as a peristaltic medical pump that must both infuse and withdraw fluid; if the withdrawal catheter is blocked, pressure stays high and an alarm sounds.
‐ Tampering or emulator use violates EU Regulation 2018/858 and can incur €30 000 fines.
‐ Operating with inactive SCR elevates NOx emissions > 800 mg/kWh (limit 400), harming air quality.
‐ Always dispose of AdBlue waste according to local hazardous-chemical rules; never flush into soil.
‐ Flow/pressure values vary slightly between Euro 5 and Euro 6 iterations—consult MAN service literature for your VIN.
‐ A minority of cases (≈4 %) trace to faulty NOx sensor feedback mis-triggering 05533; if flow is OK but code persists, check front NOx sensor diagnostics.
‐ Extended derate can immobilise the truck after 50 h of driving with active fault—plan repairs promptly.
‐ Study MAN technical info document “TI 100821 – Improved SCR Return Flow Monitoring”.
‐ Investigate urea-compatible quick-couplers that reduce crystallisation.
‐ Explore predictive maintenance models using CAN trace + machine learning to pre-empt SCR faults.
Error 5 05533-10 on a MAN TGX 480 is almost always an SCR-AdBlue return-flow blockage or dosing-pump fault. Confirm with a purge/flow test, inspect for crystallisation, check pump filter, hoses, wiring and heating. Remedy involves cleaning or replacing blocked components or the pump module, followed by code reset. Quick attention avoids power derate, fines and costly catalyst damage while maintaining compliance with current emission regulations.
