Electrical System
Central Electrical System
System Description T 80
Trucknology Generation A (TG-A)
I ELECTRICAL SYSTEM I
Please contact your MAN service centre to check whether the desired modificationlconversion
requires ex works confirmationlapprovallrelease. Fax requests for confirmationlapprovall
release to the relevant department.
Modifications subject to approval: Department TDB, Fax: ++49 (0)89 1580 4264.
Other: ... V S l T ...
Attach a copy of the vehicle documents to the fax or indicate the vehicle identification number
(FIN [VIN] = WMA ...) and vehicle number (7-digit number).
Modifications which necessitate reprogramming will be defined (in good time). Until such time,
all modifications must be carried out by trained personnel (MAN-cats II training: NFG
electronics specialists) in consultation with the Munich plant (VSlT, TDB).
We reserve the right to make modifications in the course of further development
O 1999 MAN Nutzfahrzeuge Aktiengesellschaft
Reprinting, copying or translation is not allowed without written permission from MAN
All rights under the copyright law are strictly reserved by MAN
VSWY IHA 10.1999 llbersetzung + Satz: emes GmbH
Friedrichshafen
ELECTRICAL SYSTEM
Table of contents
Electrical System .......................................................................................................................... 0
Table of contents .................................................................................................................... 0.1 1 .1
Index ............................................................................................................................................. 0.12 .1
Abbreviations ............................................................................................................................... 0.1 3 .1
General information..................................................................................................................... 1
Safety instructions ........................................................................................................................ 1.20 .1
Description of components ......................................................................................................... 4
Central electrical system .installation position ............................................................................. 4.01 .1
Central electrical system .front view ............................................................................................ 4.01 .2
Central electrical system .rear view ............................................................................................ 4.01 .4
Connector pin assignment ............................................................................................................ 4.01 .5
Central electrical system .internal wiring ..................................................................................... 4.01 .9
Diagnosis ....................................................................................................................................... 8
System structure. K-lines ............................................................................................................. 8.1 5 .1
ELECTRICAL SYSTEM
Index
Abbreviations ................................................................................................................................ 0.1 3 .1
Table of contents .......................................................................................................................... 0.1 1 .1
Safety instructions ........................................................................................................................ 1.20 .1
Connector pin assignment ............................................................................................................ 4.01 .5
Index ............................................................................................................................................. 0.12 .1
System structure .K-lines ............................................................................................................ 8.1 5 .1
Central electrical system .installation position ............................................................................. 4.01 .1
Central electrical system .internal wiring ..................................................................................... 4.01 .9
Central electrical system .rear view ............................................................................................ 4.01 .4
Central electrical system .front view ............................................................................................ 4.01 .2
ELECTRICAL SYSTEM
Abbreviations As of: 10.99
a Acceleration
ABS Anti-lock brake system
ABV Anti-skid system
ACC Adaptive cruise control
ADR International agreement for the transport of dangerous goods
AGB Automatic road speed limiter
AGND Analog ground
AGR Exhaust gas recirculation (EGR)
AHV Trailer brake valve
ALB Automatic load-dependent brake
AMA Antenna mast
ANH Trailerlsemitrailer
AS Automatic transmission
ASM Trailer control module
ASR Anti-spin regulator
ASV Trailer control valve
ATC Automatic temperature control
ATF Automatic transmission fluid
AV Exhaust valve
- BA Operator's manual
BAM Broadcast announce message
BBA Service brake system
BBV Service brake valve
BKR Brake force regulator
BV Back-up valve
BVA Brake wear indicator
BVS Brake wear sensor
BVV Brake wear sensor supply
BW German Army
BWG Brake value sensor
BZ Brake cylinder
CAN Controller area network (databus system with serial bit transmission)
CAN-H CAN-high data line
CAN-L CAN-low data line
CATS Computer-assisted testing (and diagnostic) system
CBH CAN-brake high
CBL CAN-brake low
/
CKD Completely knocked down
CNG Compressed natural gas
CPU Central processing unit
CRT Continuously regenerating trap (exhaust silencer, 2-way cat. converter, diesel particulate filter)
DA Destination address
DBR Sustained-action brake relay
DF Speed sensor
DFU Data transfer
DIA Diagnosis and information display
DlAK Diagnosis, K-line (data line)
DIAL Diagnosis, L-line (stimulation line)
DlAR Diagnosis, further stimulation
DlN German industrial standard
DKE Throttle valve increase (ASR control)
DKR Throttle valve reduction (ASR control)
DKV Throttle valve specification (ASR control)
DLB Compressed air brake system
DLC Data length code
DM1 Diagnostic message 1
L
ELECTRICAL SYSTEM
Abbreviations
DPF Diesel particulate filter
DRM Pressure control module (PCM)
DS Pressure sensor
DSV Pressure control valve
DTC Diagnostic trouble code
DV Throttle valve
DZM Rev counter
EBS Electronic brake system
ECAM Electronically controlled air management
ECAS Electronically controlled air suspension
ECU Electronic control unit
EDC Electronic diesel control
EEPROM Electrically erasable programmable read-only memory
EFR Electronic shock absorber control (ESAC)
EHAB Electrohydraulic shut-off device
ELAB Electrical shut-off device
ELF Electronic air suspension
EMS Electronic throttle control (ETC)
EMV Electromagnetic compatibility (EMC)
EOL End-of-line (programming)
E? Injection pump
ER Engine retarder (engine brake)
EV Intake valve
FBA Parking brake system
FFL Freeze frame length
FFR Vehicle management computer
FGB Road speed limiting system (RSL)
FGR Road speed governing system (RSG)
FM Vehicle management
FMI Failure mode identification
FMR Vehicle-engine regulation
FS Tachograph
GDK Controlled diesel catalytic converter
GET Gearbox
GGVS Regulations for the transport of dangerous goods
GS Gearbox control unit
GND Ground (earth)
GP Rarrge-change (planetary group)
GV Splitter
HA Rear axle
HBA Auxiliary brake system
HGB Maximum speed limiter
HST Main switch panel
HTS High sequence protection
Hz Hertz (number of cycles per second)
IBIS Integrated on-board information system
IC Integrated circuit
INA Information display
IMR Integrated mechanical relay module (starter control)
IR Individual regulation
IRM Individual regulation, modified
IS0 International Standard Organisation
ELECTRICAL SYSTEM
Abbreviations
L KBZ Combination brake cylinder
KP Kingpin
KSM Customer-specified module
KSW Customer's special request
KWP Key word protocol (protocol for MAN-cats diagnosis)
LBH Air reservoirltank
LCD Liquid crystal display
LDA Manifold-pressure compensator, aneroid device
LDF Charge air pressure sensor
LDS Air suspension/shock absorber system
LED Light emitting diode
LF Air suspension
LNG Liquefied natural gas
LPG Liquefied petroleum gas
LWR Headlight beam regulator
M-TCO Modular EU tachograph
MAN-cats MAN computer assisted testing (and diagnostic) system
ML Midline
MMI Man-machine interface
MP Motor power box (cable duct on engine block)
MR Engine governor - ASR
MV Solenoid valve
MZ Diaphragm cylinder
n Speed (rpm)
NA Power take-off (PTO)
NBF Needle movement sensor
NFG New vehicle generation
NR Commercial vehicle
NLA Trailing axle
NMG New engine generation
OC Occurrence count (errors/faults)
P Pressure
PBM Pulse width modulated signal (PWM)
PCU Pressure control unit
PDU Protocol data unit
Pm Pressure at brake line coupling head
Pme Pressure at tractor-trailer electrical connection
PTO Power take-off
PWM Pulse width modulation
RA Repair manual
RAM Random access memory
RDS Radio data system
RET Retarder
RKL Priority vehicle light
RLV Relay valve
ROM Read only memory
SA Source address
SAE Society of Automotive Engineers
SAMT Semi automatic mechanical transmission
ELECTRICAL SYSTEM
Abbreviations
SD Silencer
sec Second
SG Control unit
SH Select-high control
SKD Semi knocked down
SL Select-low control
SPN Suspect parameter number (fault location number)
SSM Select-smart control
STCO System tachograph
t Time
TC Traction control
TCM Trailer control module
TKU Technical customer document
TMC Traffic message channel
TRS Technical directive, on-road
UBAT Battery voltage
v Velocity (road speed)
VA Front axle
VG Transfer case
VLA Leading axle
WA Maintenance manual
WLE Swap-body unit
WR Warning relay
WS Travel sensor
WSK Torque converter and clutch system
z Retardationlbraking factor
ZBR Central on-board computer
ZBRO Central on-board bus computer
ZDR Intermediate speed governing (ISG)
ZE Central electrical system (CES)
h Slip
I' Coefficient of friction
I'c Microcontroller
GENERAL INFORMATION
Safety instructions
This survey presents a summary of the important regulations listed according to major topics. The intention
is to provide the knowledge needed to avoid accidents which could lead to injury, damage and
environmental pollution.
Additional information is given in the operator's manual for the vehicle.
Important:
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident
involves skin contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze
spraying into eyes, etc.
Regulations for preventiug accidents leading to injury to personnel.
Only authorised technical personnel are entitled to perform inspection, adjustment and repair work.
Secure the vehicle to prevent it from rolling away.
Support the frame when working on the pneumatic or spring suspension system.
Secure units during their removal.
Only authorised personnel are permitted to start and operate an engine.
Do not approach moving parts of a running engine too closely.
Do not wear baggy clothing.
Do not touch an engine with your bare hands when it is at operating temperature:
Danger of burns!
Keep the area around the engine, ladders and steps free of oil and grease.
Accidents caused by slipping can have very serious consequences.
Only use tools that are in perfect condition. Damaged or widened spanners can
slip: Risk of injury!
No-one is allowed to stand under an engine suspended from a crane hook.
- Keep all lifting tackle in good condition. -
Collect any brake fluid that leaks out. Treat brake fluid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.
Brake fluid is poisonous! Do not allow it to come into contact with food or open
wounds.
Do not open the coolant circuit until the engine has cooled down. Refer to the
"Maintenance and care jobs" section in the Operator's Manual if you absolutely
have to open the circuit when the engine is warm.
Do not attempt to tighten, loosen or open pipelines and hoses (e.g. in lubrication
circuit, coolant circuit or any subsequent hydraulic oil circuit) whilst they are
pressurised. Fluid spraying out represents an injury hazard!
Do not hold your hands under the jet of fuel when checking the injector nozzles.
Do not inhale fuel vapours.
GENERAL INFORMATION
Always disconnect the batteries before working on the electrical system.
Important! Oxyhydrogen gas may form in enclosed battery boxes. When the
batteries are disconnected this gas may be ignited by sparks produced by other
continuously operating consumers, the tachograph etc. that cannot be shut down.
Blow compressed air through the battery box before disconnecting the batteries!
Only tow-start the vehicle if the batteries are connected (minimum charge 40%)!
Do not use a boost-charger to jump-start the vehicle! Always disconnect the
positive and negative leads before boost-charging batteries!
Disconnect the batteries or recharge them every 4 weeks if the vehicle is not in
use.
Caution! Battery acid is poisonous and corrosive. Battery gases are explosive.
Follow the manufacturer's instructions when handling batteries.
Measure voltage only using a suitable measurement device!
The input resistance of the measurement device must be at least 10 MR.
The ignition must be switched off before the wiring harness plugs of the
p, -!me
electronic control units are disconnected or connected up!
When performing electric welding work, connect up the "ANTIZAP SERVICE
A
MONITOR" protective device (MAN item number 80.78010.0001) in accordance with
the instructions provided with the device.
If this device is not available, disconnect the batteries and join the positive cable to
the negative cable in order to make a conductive connection.
Always earth the welding equipment as close as possible to the welding area. Do not
lay the welding equipment cables parallel to electrical cables in the vehicle.
Refer to the "Guidelines for Welders" for further safety precautions.
The chassis is not intended for use as an earth return.
If attachments are to be fitted to the vehicle (e.g. a tailgate lift), additional earth
(ground) lines with an adequate cross-section must be fitted as well. Otherwise
the earth connection may be created along wire cables, wiring harnesses,
gearbox shafts, gears etc. and severe damage could result.
If paint spraying is to be carried out, do not expose the electronic components
to high temperatures (max. 95 "C) for more than brief periods; a time of up to
2 hours is permissible at a maximum of 85 "C. Disconnect the batteries.
ACHTUNG!
Plastic tubes
Important! - Danger of damage and fire!
The warning sign opposite is attached to the co-driver door beneath the door
lock. It warns you against welding or drilling near to plastic tubes. ,
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POLYWIDROHRE
TUBE P W E
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PLASTIC TUBE
I GENERAL INFORMATION
Working on parts containing asbestos
.- Certain vehicle components may contain asbestos.
Spare parts and, if necessary, their packaging, are marked
accordingly - see the illustration.
Asbestos dust may be released when parts containing
asbestos are machined.
Please take the necessary precautionary measures and
observe the following safety advice to avoid possible damage
to your health:
If possible, carry out the work in question in the open or in an
area equipped with an efficient ventilation system!
If possible, use hand-operated or slow-running tools equipped
with a dust-collector if required!
Fast-running tools should always be fitted with such a device.
If possible, wet the workpiece prior to cutting or drilling!
Spray the dust with water, seal it in a container with a tight-
fitting lid and dispose of it as hazardous waste in an
environmentally sound manner!
Limited liability for accessories and parts
In your own interests, you are recommended to use only accessories expressly approved by MAN and
genuine MAN parts. The reliability, safety and suitability of these parts and accessories have been
determined specifically for MAN vehicles. Despite constant market observation, we cannot judge the
aspects of other products, nor can we accept responsibility for them - even if they have been approved or
authorised by an official body.
Attachments and special bodies
You must comply with the safety instructions and regulations issued by the body maker in question if
attachments or special bodies are fitted.
Taking out of operation or putting into storage
The special measures described in MAN Works Standard M 3069 Part 3 apply if buses or trucks are to be
-- withdrawn from service or stored for a period longer than 3 months.
DESCRIP'I'ION OF COMPONENTS
Central electrical system (equipment no. A1 00)
Installation position
The central electrical system is located on the right inside the vehicle (left-hand drive vehicles). It is behind
a cover in the centre console.
The fuse and relay arrangement is depicted on the adhesive label on the inside of the cover.
DESCRIPTION OF COMPONENTS
-
Central electrical system front view
DESCRIPTION OF COMPONENTS (
ZE = Connector, central electrical system (CES)
(refer to central electrical system internal wiring)
I DESCRIPTION OF COMPONENTS I
-
Central electrical system rear view
DESCRIPTION OF COMPONENTS
Connector pin assignment
Connector A1
14 15002 Terminal 15, central on-board computer
15 15002 Jumper to A2114
16 58000 Terminal 58
17 58000 Terminal 58
18 16006 Terminal 15, instrumentationltachograph
Connector A2
15 15001 Terminal 15
16 15001 Terminal 15
17 30000 Terminal 30
18 --- Not used
DESCRIPTION OF COMPONENTS
Connector A3
Connector B
Connector C
Connector D
DESCRIPTION OF COMPONENTS
Connector F
Connector G
Connector H
Connector I
Pin 9011
Connected with 9012 via jumper X I 364
Terminal 30, steering lock
Terminal 30, working spotlight
Terminal 30, cargo space lighting
Terminal 30, refrigerator compartment
Terminal 30, sliding roof
Terminal 30, cab tilt mechanism, electric
Terminal 30, auxiliary heater
DESCRIPTION OF COMPONENTS
Pin 9012
Connected with 9011 via jumper X I 364 and with 91 via jumper XI365
Terminal 30 from engine
Terminal 30 for 12 V - socket
Terminal 30 for 24 V - socket
Terminal 30 for sunblind, electric
Pin 91
Connected with 9012 via jumper XI365
Terminal 30, cigarette lighter
Terminal 30, windscreen heater
Terminal 30, AS-Tronic
Pin 92
Ground from engine
Ground to earthing point, cab
Pin 94
Terminal 15, jumper to fuse F152 (number 10) and F399 (number 11)
Terminal 15, AS-Tronic
Terminal 15, seat heatinglseat adjustment
Terminal 15, set-up, followingltrailing control-semitrailer
Terminal 15, tailgate
Pin 95
Central on-board computer-ground from engine
Central on-board computer-ground, various consumers (XI 830)
Central on-board computer-ground to central on-board computer
Central on-board computer-ground to central on-board computer
Pin 96
Not yet used
DESCRIPTION OF COMPONENTS
-
Central electrical system internal wiring
ZE = Connector, central electrical systemlcentral on-board computer (CES)
1 Parking light, tractor, right Connected with CES 12
2 Parking light, trailer, left Connected with CES 11
3 Parking light, trailer, right Terminal 30 via battery master switch
4 Relay, parking lights Power supply, parking light, left
5 Starter, terminal 50 Connected with CES 16
6 Relay, wiper interval Connected with CES 15
7 Parking light, tractor, left Terminal 15
8 Relay, flame start Terminal 30, not switched
9 Terminal 30 via battery master switch Flame start, input
10 Power supply, parking light, right Flame start, output
DIAGNOSIS
System structure, K-lines
u All the control units testable using the MAN-cats diagnostic system are connected with diagnosis socket
X200 pin ... via a K-line. The diagnostic system stimulates a certain control unit via the K-line. The control
unit replies and digitally transfers the faults stored in the fault memory via the K-line.
GET
-
HZG
ECAM
KLlMA -
EBS
AIRBAG -
ECASI
EFR
FSS -
ACC Adaptive cruise control GET Gearbox control unit
AIRBAG Airbag control unit HZG Heating control
DPFIGDK Diesel particulate filter/ KLlMA Air-conditioning system
controlled diesel catalytic converter KSM Customer-specified module
EBS Electronic brake system RET Retarderllntarder control
ECAM Electronically controlled air management TM Door module, driver side
ECASIEFR Electronic air suspension TM1 Door module, co-driver side
EDC Electronic diesel control ZBR II Central on-board computer
FFR Vehicle management computer X200 Diagnosis socket
FSS Driver seat control unit
