Man Edc

Electrical system
Power Train Manager (PTM)

Trucknology Generation (TGS/TGX)
Editorial deadline 02/2012
System description
81.99298-7652 1st edition T 160
MAN Truck & Bus AG Systembeschreibung T 160, 1. Ausgabe
Dachauer Str. 667 Elektrische Anlage
80995 MÜNCHEN Power Train Manager (PTM)
oder Trucknology Generation (TGS/TGX)
Postfach 50 06 20 - Englisch -
80976 MÜNCHEN Printed in Germany
System description T 160
1st edition
Electrical system
Power Train Manager (PTM)
Trucknology Generation (TGS/TGX)
81.99298-7652
1
PREFACE/PUBLICATION DATA
PREFACE
This repair manual is intended to provide assistance in performing repairs correctly on vehicles and units.
The technical details were correct at the time of going to press.
This publication assumes that persons who use it possess the requisite technical knowledge in handling
vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do not always
correspond to the unit or peripherals in question, but this does not necessarily mean they are incorrect. In
such cases, plan and carry out the repair work in accordance with the sense of the instructions.
Repair work on complex add-on units should be entrusted to our customer service or to the customer service
of the manufacturing company. These units are mentioned specically in the text.
Important instructions concerning technical safety and the safety of personnel are specically highlighted, as
indicated below.
CAUTION
Type and source of danger
Refers to working and operating procedures which must be followed in order to avoid exposing
people to risk.
WARNING
Type and source of danger
Refers to working and operating procedures which must be followed in order to avoid material
damage or destruction.
Note
An explanatory note which is useful for understanding the working or operating procedure to be
performed.
Comply with general safety regulations when performing any repair work.
Yours faithfully,
MAN Truck & Bus AG
PUBLICATION DATA
We reserve the right to make modications in the course of further development.
© 2012 MAN Truck & Bus AG
Reprinting, copying or translation, even of extracts, is not permitted without the written approval of MAN Truck
& Bus AG.
All rights under the copyright law are strictly reserved by MAN Truck & Bus AG.
If any changes are made without the written approval of MAN Truck & Bus AG then MAN Truck & Bus AG
shall not be liable for any warranty or guarantee claims arising from damage and defects attributable to the
unauthorised modication. Furthermore, MAN Truck & Bus AG shall not be liable for any damage resulting
from the unapproved modication.
Editorial Department: SAWAS-Y, WT, RM, 02/2012
Typesetting: SAWAS-Y
Printing: MAN-Werksdruckerei (on-site printing works)
2 T 160 1st edition

TABLE OF CONTENTS
Content Chapter/Page
Index 5
Abbreviations 7
Introduction
Safety instructions ....................................................................................................... 15

Type overview ............................................................................................................ 22
Operating instructions for circuit diagrams .......................................................................... 23
Device description
System description ...................................................................................................... 27

General ................................................................................................................ 27
CAN data bus system structure ................................................................................... 28
Functional description .................................................................................................. 30
Power Train Manager (A1124) .................................................................................... 30
Pedal unit ............................................................................................................. 36
Fan clutch with speed sensor (A968) ............................................................................ 41
Multi-function steering wheel (A943) ............................................................................. 43
LIN data bus .......................................................................................................... 45
Description of components ............................................................................................ 47
Power Train Manager (A1124) .................................................................................... 47
Accelerator (A410) .................................................................................................. 48
Fan clutch with speed sensor (A968) ............................................................................ 49
Multi-function steering wheel (A943) ............................................................................. 50
Diagnostics ............................................................................................................... 51
General ................................................................................................................ 51
SPN – diagnostic code description ............................................................................... 59
Test step list ........................................................................................................ 115
Additional circuit diagrams
Brief overviews ......................................................................................................... 137

Brief overview of LIN data bus with multi-function steering wheel, PTM version (TGS/TGX) ....... 138
Quick overview of LIN data bus without multi-function steering wheel, PTM version (TGS/TGX) .. 140
Quick overview of Power Train Manager (TGS/TGX) - page 1 of 3 ...................................... 142
T 160 1st edition 3

INDEX
Catchword Page
A
Accelerator (A410)......................................................................................................................................... 36
Components ............................................................................................................................................. 48
B
Break box ...................................................................................................................................................... 56
C
CAN data bus system structure..................................................................................................................... 28
Clutch functional test ..................................................................................................................................... 39
D
Diagnostic socket HD-OBD (X200) ............................................................................................................... 51
F
Fan clutch with speed sensor (A968)
Components ............................................................................................................................................. 49
Fan clutch with speed sensor (A968), function.............................................................................................. 41
Fluke ScopeMeter 123 .................................................................................................................................. 58
G
General
Diagnostics............................................................................................................................................... 51
System ..................................................................................................................................................... 27
I
Installation location of diagnostic socket ....................................................................................................... 52
Installation locations for location designations .............................................................................................. 24
Interfaces to other systems ........................................................................................................................... 28
L
LIN data bus
Function.................................................................................................................................................... 45
M
Main functions of the diagnostics .................................................................................................................. 52
Malfunction indicators.................................................................................................................................... 52
Multi-function measuring device – multimeter ............................................................................................... 57
Multi-function steering wheel (A943)
Components ............................................................................................................................................. 50
Function.................................................................................................................................................... 43
O
Operating instructions for circuit diagrams .................................................................................................... 23
P
Pedal unit
Function.................................................................................................................................................... 36
Power Train Manager (A1124)
Components ............................................................................................................................................. 47
Function.................................................................................................................................................... 30
S
Safety instructions ......................................................................................................................................... 15
General..................................................................................................................................................... 15
SPN – diagnostic code description................................................................................................................ 59
Status display, FMI (Failure Mode Identication)........................................................................................... 53
Structure of the fault texts in the diagnostic message ................................................................................... 54
T
Test step list................................................................................................................................................. 115
T 160 1st edition 5

INDEX
Test step list for Power Train Manager (A1124)........................................................................................... 115

Troubleshooting program .............................................................................................................................. 58
Trucknology Generation X (01X - 99X) type overview .................................................................................. 22
Type overview for Trucknology Generation S (01S - 99S, 01W-99W) .......................................................... 22
6 T 160 1st edition

LIST OF ABBREVIATIONS
Abbreviations
A
a Acceleration
ABE General operating permit
ABS Anti-lock braking system
ABV Automatic anti-lock braking system
AC Air-conditioning system
ACC Adaptive Cruise Control
ACK Acknowledge
ADC Analogue-digital converter (conversion of analogue signals into digital signals)
ADR European Agreement concerning the International Carriage of Dangerous Goods by Road
AGB Automatic speed limiter
AGND Analogue ground
AGR Exhaust gas recirculation (EGR)
AHK Trailer coupling
AHV Trailer brake valve
ALB Automatic load-dependent brake force regulation
ALM Axle load monitoring
AMA Antenna mast system
AMR Anisotropic magneto-resistive
ANH Trailer/semitrailer
ANS Automatic shift into neutral
AS Automatic gearbox
ASD Trailer socket
ASM Trailer control module
ASR Anti-spin regulator
ASV Trailer control valve
ATC Automatic temperature control
ATF Automatic transmission uid (automatic gearbox oil)
AU Exhaust-gas inspection
AV Exhaust valve
AVS Automatic preselection system
B
BA Operator's Manual
BBA Service brake system
BBV Service brake valve
BG Operating unit
BHTC Behr Hella Thermocontrol
BITE Built-in test
BKR Brake force regulator
BUGH Front heater
BV Backup valve
BVA Brake lining wear display
BVS Brake lining wear sensor
BVV Brake lining wear sensor – supply
BW German Army
BWG Braking value sensor
BZ Brake cylinder(s)
C
CAN Controller Area Network (data bus system with bit-serial transfer)
CAN-H CAN-High data line
CAN-L CAN-Low data line
CATS Computer-assisted testing and diagnostic system
CBU Central brake unit
CDC Continuous damping control
CCVS Cruise control vehicle speed (cruise control)
CKD Completely knocked down
CNG Compressed natural gas
CPU Central processing unit (central computer)
T 160 1st edition 7

CRT Continuously regenerating trap (exhaust silencer, oxidising catalytic converter, diesel particulate
lter)
CRC Cyclic redundancy check
CS Comfort shift
D
DAHL Roof ventilator
DBR Continuous brake relay
DCU Dosing control unit (AdBlue metering)
DF Speed sensor
DFÜ Data communication
DIA Diagnostics and information display
DIAG Complete vehicle diagnostics
DIAG - Complete vehicle diagnostics – multiplex central computer (bus/coach only)
MUX
DIAK Diagnostics, communication line
DIAL Diagnostics, L line (response line)
DIAR Diagnostics, further response
DIN German Institute for Standardization
DKE Throttle valve increase (ASR regulation)
DKH Roof duct heating
DKL Roof-mounted air inlets
DKR Throttle valve reduction (reduction request from ASR to EDC/EMS)
DKV Throttle valve setpoint (load sensor signal from EDC/EMS pedal-travel sensor)
DLB Compressed-air brake system
DM Diagnostic message
DNR Drive Neutral Reverse (multi-function switch for automatic)
DPF Diesel particulate lter
DRM Axle modulator
DRS Yaw rate sensor
DS Pressure sensor
DSV Pressure control valve
DTC Diagnostic trouble code (OBD diagnostic code)
DTCO Digital tachograph
DV Throttle valve
DWA Anti-theft warning system
DZG Speed sensor
DZM Rev counter
E
E-AGR Position-controlled exhaust gas recirculation (E-EGR)
EBS Electronic brake system
ECAM Electronically controlled air management
ECAS Electronically controlled air suspension
ECE Emergency shut-off according to ECE 36
ECU Electronic control unit
EDC Electronic diesel control
EDC S Electronic diesel control slave
EDM Electronic diesel consumption measuring system
EDR Maximum speed governor
EEC Electronic engine controller
EEPROM Electrically Erasable Programmable Read Only Memory
EFR Electronic running gear control
EFS Electric driver's seat
EHAB Electro-hydraulic shut-off device
EHLA Electro-hydraulic steering system
ELAB Electrical shut-off device
ELF Electronically controlled air suspension (ECAS)
EMS Electronic engine control
EMV Electromagnetic compatibility (EMC)
EOBD European on-board diagnosis
8 T 160 1st edition

EOL End of line (programming)

EP Injection pump
ER Engine retarder (engine brake)
ESAC Electronic shock absorber control
ESP Electronic stability program
ESR Electronic roller sunblind
EST Electronic control unit
EV Inlet valve
EVB Exhaust valve brake
F
FAP Driver's workplace
FAQ Frequently asked questions
FBA Parking brake system
FBM Footbrake module
FDR Ride dynamics control
FDF Vehicle data le
FFR Vehicle management computer
FGB Road speed limiter
FGR Cruise control
FHS Cab
FIN Vehicle identier (17 digits)
FM Vehicle management
FMI Failure mode identication (fault type)
FMS Fleet management standard (manufacturer-independent telematics standard)
FMR Vehicle engine control
FOC Front omnibus chassis (bus/coach chassis with front-mounted engine)
FSCH Windscreen heating
FSG Tracks for difcult terrain
FSH Window mirror heater
FTW Driver's partition
FUNK Radio installation
FZA Destination system
FZNR Vehicle number (7-digits)
G
GDK Regulated diesel catalytic converter
GEN Alternator
GET Gearbox
GGVS European Agreement concerning the International Carriage of Dangerous Goods by Road (ADR)
GND Ground
GP Gearbox planetary group (range-change group)
GS Gearbox control
GV Gearbox splitter box
H
HA Rear axle (RA)
HBA Secondary braking system
HD-OBD Heavy duty on-board diagnosis
HDS Urea metering system
HGB Maximum speed limitation
HGS Hydraulic gearshift
HLUE Hydrostatic fan
HOC Rear bus/coach chassis (bus/coach chassis with rear engine)
HSS Highside switch
HST Main control panel
HU Main inspection
HYD Hydronic auxiliary heater
HYDRIVE Hydrostatic front-wheel drive control unit
HYDRO MAN HydroDrive
HVA Hydrostatic front-axle drive
Hz Hertz (change/period per sec)
T 160 1st edition 9

HZA Stop signal system

HZG Auxiliary speed sensor
I
IBEL Interior lighting
IBIS Integrated on-board information system
IC Integrated circuit
ICOM VDO-specic data bus
ID Identication
IMR Integrated mechanical relay (start control)
INA Information display (e.g. check lamp)
INST Combined instrument
IR Individual regulation (ABS)
IRM Individual regulation modied (ABS)
ISO International Organization for Standardization
IWZ Incremental angle and time measurement system
K
KBZ Combination brake cylinder
KFH Fuel lter heating
KITAS Kienzle intelligent tachograph sensor
KLI Air-conditioning system
KNEEL Kneeling
KSM Customer-specic control module (control unit for external data exchange)
KSW Customer special request
KWP Key word protocol (protocol for diagnostics with MAN-cats KWP 2000)
L
LBH Air tank
LCD Liquid crystal display
LDA Charging pressure-dependent full-load stop
LDF Charging pressure sensor
LDS Air suspension damper system
LED Light emitting diode
LF Air suspension
LGS Lane Guard System
LIN Local Interconnect Network (data bus system)
LL Idling speed
LLA Idling speed increase
LLR Idling speed control
LNA Steered trailing axle
LNG Liqueed natural gas
LOE Steering oil monitoring
LPG Liqueed petroleum gas
LSVA Heavy vehicle fee (HVF)
LWR Headlight beam regulator
LWS Steering angle sensor
M
M-TCO Modular EU tachograph
MAB Solenoid valve stop (engine shut-off via high-pressure solenoid valve in the injection pump)
MAN-cats MAN-computer-assisted testing and diagnostic system
MAR Solenoid valve stop relay (redundant engine shut-off relay)
MDB Main control board
MES Flow regulator
MFL Multi-function steering wheel
MIL Malfunction indicator lamp (OBD fault lamp)
ML Midline
MMI Man-machine interface
MOTB Engine brake
MP MP box (cable channel at engine block)
MR Engine regulator – ASR
10 T 160 1st edition

MSG EDC engine control unit

MUX Multiplex central computer (bus/coach only)
MV Solenoid valve
MZ Diaphragm brake cylinder
N
n Speed
NA Power take-off (PTO)
NBF Needle movement sensor
NES New electronics structure
NFZ Commercial vehicle
NLA Trailing axle (TA)
NOx Nitrogen oxides
NSL Rear fog lamp
NSW Fog lights
O
OBD On-board diagnosis
OBDU On-board diagnostic unit (subsystem of the central on-board computer)
OC Occurrence count (error frequency counter)
OEAB Oil separator
OENF Oil top-up
P
p Pressure
P Powertrain (driveline)
PBM Pulse breadth modulation (pulse-width modulated signal, see also PWM)
P-Code Powertrain code (powertrain/driveline diagnostic code)
PDF Diesel particulate lter
PLM Programmable logic module
PM-Kat PM catalytic converter
PSC Pneumatic supply controller – replacement for ECAM
PSG Pump control unit (EDC)
PTM Power Train Manager (replacement for vehicle management computer)
PTO Power take-off
PWG Pedal-travel sensor
PWM Pulse width modulation (pulse-width-modulated signal, see also PBM)
R
RA Repair manual
RAH Cab heating
RAM Random Access Memory (volatile read/write memory)
RAS Rear axle steering (steered rear axle)
RAS-EC Rear axle steering, electronically controlled (electronically controlled steered rear axle)
RDRA Tyre pressure control system
RDS Radio Data System
RET Retarder
RET P Primary retarder
RET S Secondary retarder
RKL Revolving beacon
RKS Tyre monitoring system – replaced by TPM
RLV Relay valve
RME Rape methyl ester (biodiesel)
ROM Read-only memory
S
SA Optional equipment
SAE Society of Automotive Engineers
SAMT Semi-automatic mechanical transmission
SB Service outlet
SBW-RA Steer by wire rear axle (electronically controlled steered trailing axle)
SCR Selective Catalytic Reduction
T 160 1st edition 11

sec Second
SER Standard
SG Control unit (CU)
SH Select high control (ABS)
SKD Semi knocked down
SL Select low control (ABS)
SML Side marker lights
SPI Serial peripheral interface
SPN Suspect parameter number
SRE Stoneridge Electronics
SSG Standard control unit (heater unit, air conditioner)
STA Engine start/STOP
SWR Headlight cleaning system
T
t Time
TBM On-board telematics module
TC Traction control (anti-spin regulator)
TCM Trailer control module
TCO Tachograph (MTCO, DTCO, TSU, etc.)
TCU Transmission control unit
TEPS Twin electronic platform systems (bus/coach only)
TGA Trucknology Generation A
TGL Trucknology Generation Light
TGM Trucknology Generation Mid
TGS Trucknology Generation S
TGX Trucknology Generation X
TKU Technical customer document
TMC Trafc Message Channel
TPM Tyre pressure module
TRS Technical guideline for roads
TSC Torque speed control (brake torque)
TSU Tachograph simulating unit (for vehicles without MTCO/DTCO)
TUER Door control
U
UBat Battery voltage
UDF Conversion data le
UDS Accident data memory
V
v Speed
VA Front axle (FA)
VDF Vehicle data le
VG Transfer case or in accordance with defence equipment standards
VIN Vehicle Identication Number
VLA Leading axle (LA)
VSM Transfer case lock management
W
WA Maintenance manual
WAB Water trap
WaPu Coolant pump, intarder
WLE Swap body unit
WR Warning relay
WS Displacement sensor
WSK Converter-clutch unit
Z
z Braking
ZBR Central on-board computer
ZBRO Central on-board computer, bus/coach

ZDR Intermediate speed control

ZE Central electrical system
ZFR Additional vehicle computer
ZR Central computer
ZS Central lubrication system
ZUSH Auxiliary heater
ZWS Time-based maintenance system
λ Slip
µ Coefcient of friction
µC Microcontroller (microprocessor)

INTRODUCTION
INTRODUCTION
SAFETY INSTRUCTIONS
General
Only trained personnel are permitted to perform operating, maintenance or repair work on trucks and buses
/coaches.
The following sections include summaries of important regulations listed according to major topics. These
must be observed, in order to avoid accidents which could lead to injury, damage and environmental pollution.
They constitute only a short extract from the numerous accident prevention guidelines. Of course, all other
safety regulations must be followed and the necessary measures must be taken.
Additional references to danger are contained in the instructions at points where there is a potential danger.
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,
crushing limbs, etc.
1. Regulations for preventing accidents leading to injury to personnel
During inspection, adjustment and repair work

– Secure units during their removal.
– Support the frame when working on the air or spring suspension system.
– Keep units, ladders, stairs, steps and the surrounding area free from oil and grease.
– Do not use any tools that are not in perfect condition.
– Only authorised technical personnel are entitled to perform inspection, adjustment and repair work.
Working on the brake system

– Please use a dust extraction device if dust is released during work on the brake system.
– Perform visual, functional and effectiveness checks on the brake system after carrying out any work on it
whatsoever. These safety inspection checks (SP) must be made in accordance with the relevant statutory
regulations governing special brake inspections.
– Use a suitable test system (e.g. MAN-cats) to check the function of the ABS/ASR systems.
– Collect any brake uid that leaks out.
– Brake uid is poisonous! Do not allow it to come into contact with food or open wounds.
– Treat hydraulic uid/brake uid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.
Working on vehicles with a compressed natural gas (CNG) system

– Vehicles with a defective compressed natural gas system may not be brought into the workshop. This also
applies to vehicles whose engines cannot be switched off by automatic emptying of the supply lines.
– When working on vehicles with a compressed natural gas system, set up a gas warning device above the
vehicle roof and in the engine compartment above the pressure governor. Further gas warning devices
must be carried by the persons working on the vehicle.
– Smoking is not allowed in areas where work on vehicles with compressed natural gas systems is carried
out. All sources of ignition must be removed from these areas.
– Before carrying out welding, the gas tanks must be removed and the gas-carrying lines must be ushed
with inert gas.
– Gas tanks must not be subject to temperatures in excess of 60°C in painting and drying booths. If
temperatures exceed this value, the gas tanks must be removed or degassed and ushed with inert gas
(e.g. nitrogen). Furthermore, gas-carrying lines must be ushed with inert gas.
Working on the compressed natural gas (CNG) system

– Work on the compressed natural gas system may only be carried out by persons who have been specically
trained to do so.
– The working area for the compressed natural gas system must be equipped with an adequate ventilation
system. The ventilation system must replace the air in the room with new air at least three times per hour.
– After following the prescribed procedures to replace standard-t components of the compressed natural
gas system, check the assembly points for leaks. Perform these checks using a leak indicator spray or a
gas warning device.

INTRODUCTION
Operating the engine

– Only authorised personnel are permitted to start and operate an engine.
– Do not get too close to the moving parts of a running engine and do not wear baggy clothing. Use an
extractor system in enclosed spaces.
– Risk of burning when working on engines at operating temperature.
– Danger of scalding when opening the hot cooling circuit.
Suspended loads
– Persons may not stand or walk underneath suspended loads.
– Only use suitable hoists that are in top condition technically. Please also make sure that the load suspension
devices used have sufcient load capacity.
Bodies and special bodies

– Comply with the safety instructions and regulations issued by the body manufacturer in question if bodies
or special bodies are tted.
Working on high-pressure lines

– Do not attempt to tighten, loosen or open pipes and hoses (e.g. in the lubrication circuit, coolant circuit and
hydraulic oil circuit) whilst they are pressurised:
Risk of injury from liquids escaping under pressure.
Testing injection nozzles

– Please wear the relevant protective equipment.
– Keep all body parts away from the jet of fuel when checking the injection nozzles.
– Do not breathe in fuel vapour, ensure sufcient ventilation.
Work on the vehicle electrical system

– Do not disconnect the batteries whilst the engine is running!
– Always disconnect the batteries when working on vehicle electronics, central electrical system, alternators
and starters. Disconnect the negative terminal rst when disconnecting the battery. Connect the positive
terminal rst when connecting.
– Use only matching test lines or test adapters to measure at plug connectors.
– If you expect temperatures in excess of 80°C (e.g. in the dryer after painting), set the main battery switch
to "OFF" and then remove the control units.
– The frame is not intended for use as a ground return. If attachments are to be tted to the vehicle (e.g. a
wheelchair lift), additional ground cables with an adequate cross-section must be routed as well. Otherwise
the ground connection may be created along wire cables, cable harnesses, gearbox shafts, gears, etc.
Severe damage could result.
Important: battery gases are explosive!

– Oxyhydrogen gas may form in enclosed battery boxes. Take particular care after long journeys and after
charging the batteries with a battery charger.
– When the batteries are disconnected, the gas may be ignited by sparks produced by continuously operating
consumers, tachographs, etc. that cannot be switched off. Blow compressed air through the battery box
before disconnecting the batteries.
– Only tow-start a vehicle if the batteries are connected. Tow-start vehicles only if the check lamps light up
brightly, but there is insufcient battery power to start the vehicle.
Do not use a boost-charger to jump-start the vehicle!
– Always disconnect the positive cable and ground cable before boost-charging and charging batteries!
– Do not boost-charge lead gel and maintenance-free batteries. (not for "maintenance-free according to DIN")
Maximum loading capacity is 10% of the stated capacity of each battery. Parallel connections increase
capacity according to the number of batteries connected in parallel.
– Risk of short-circuit if batteries have been incorrectly connected.
– Do not place any metal objects (keys, pliers, etc.) on the batteries otherwise there may be a short-circuit
at the terminals. Risk of short-circuit.
– Disconnect the batteries and recharge them every 4 weeks if the vehicle is not in use over a prolonged
period of time.
Caution! Battery acid is poisonous and corrosive!

– Wear suitable protective clothing (gloves) when handling batteries.
Do not tip or tilt batteries as acid may emerge. Do not tip or tilt gel batteries either.

INTRODUCTION
– Only measure voltage with suitable measuring devices! The input resistance of a measuring device should
be at least 10 MΩ.
– Connect/disconnect the plug connectors of electrical control units only when the ignition is switched off.
Electric welding
– Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN item number 80.78010.0002) as
described in the instructions accompanying the device.
– If this device is not available, disconnect the batteries and rmly connect the positive cable to the ground
cable in order to make a conductive connection.
– The manually operated main battery switch is in the driving mode position. If an electronic main battery
switch has been tted, bypass the “negative” at the power relay contacts (jumper cable > 1 mm2) and
bypass the “positive” at the power relay load contacts. Also switch on numerous power consumers, such
as: starter switch (ignition) in driving mode position, hazard warning system switch “on”, lighting switch in
position “low-beam headlights on”, fan ventilation to “maximum”. The more consumers are switched on,
the higher the protection.
When welding is complete, rst switch off all consumers and remove all jumpered connections (reset to
original condition) before connecting the batteries.
– Always ground the welding equipment as close as possible to the welding area. Do not route the welding
equipment cable parallel to the electrical cables in the vehicle.
Work on plastic tubes – risk of damage and re

– Plastic tubes must not be subject to mechanical or thermal load.
Painting work
– During painting work, electronic components may only be exposed to high temperatures (max. 95°C) for
short periods; a period of up to approx. 2 hours is permissible at max. 85°C; disconnect the batteries.
Do not paint the bolt connections of the high-pressure section of the injection system. Danger of ingress of
dirt when repair work is carried out.
Working with a tilted cab

– Keep the tilting area in front of the cab clear.
– Stay out of the area between the cab and the chassis while the cab is being tilted! Danger zone!
– Always tilt the cab over the tipping point or secure the cab with a prop.
Work on the air-conditioning system

– Refrigerant uids and vapours represent a health hazard, avoid contact and protect eyes and hands.
– Do not drain gaseous refrigerants in enclosed areas.
– Never mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant.
– Dispose of refrigerant according to instructions.
Work on the airbag or belt pretensioner units

– Work on airbags or belt pretensioner units must only be performed by personnel that can provide proof of
a specialist course at the MAN Service Academy.
– Mechanical loads, impacts, heating to over 140°C, electrical pulses and electrostatic discharge may trigger
unwanted ignition of the airbag or belt pretensioner units.
– Hot gases are released explosively when the airbag or belt pretensioner units are triggered. Airbag or belt
pretensioner units that are not tted may be catapulted around uncontrollably. For this reason, there is a
risk of injury for persons in or near the cab.
– Risk of burning when touching the hot surfaces after the airbag has been triggered.
– Do not open a triggered airbag or air cushion.
– Do not touch a triggered airbag with a destroyed air cushion with your bare hands. Wear protective gloves
made of nitrile rubber.
– Before performing any work and inspections on the airbag or belt pretensioner units, or working on the
vehicle where impacts are likely, it is necessary to switch off the ignition, remove the key from the ignition
lock, disconnect the ground cable from the battery and disconnect the plug connector for the airbag and
belt pretensioner power supply.
– Fit the driver airbag restraint system, MAN item number 81.66900-6035, to the airbag steering wheel as
instructed in the Operator's Manual.
– Only perform inspections on airbag and belt pretensioner units with devices specically intended for this
purpose. Do not use inspection lamps, voltmeters or resistance meters.

INTRODUCTION
– After having nished all work and inspections, switch off the ignition rst, then connect the plug connector(s)
for the airbag and belt pretensioner and, as a last step, connect the battery. Please ensure there is no one
in the cab when doing this.
– Only place airbag units individually, with the impact cushion facing up.
– Do not apply grease or cleaning agents to airbags and belt pretensioners.
– Store and transport airbag and belt pretensioner units in their original packaging only. It is not permitted to
transport them inside the passenger compartment.
– Airbag and belt pretensioner units may only be stored in storage areas that can be locked, and up to a
maximum of 200 kg.
Working on the independent heating

– It is necessary to switch off the heater unit and allow all hot components to cool down before beginning
work.
– Ensure that suitable collecting containers are available and that no sources of ignition are present when
working on the fuel system.
– Keep suitable re extinguishing equipment nearby and within easy reach!
– The heater unit must not be operated in enclosed areas such as garages or workshops without an extractor
system.
2. Guidelines for preventing damage and premature wear on units
General
– Units are only built for the purpose designated in the scope of delivery (according to their intended use),
which is dened by the device manufacturer: Any other use is classied as not in accordance with the
designated use. The manufacturer does not assume liability for any damage resulting from this. Any other
use is carried out at user's risk only.
– The intended use also includes compliance with the operating, maintenance and repair conditions dened
by the manufacturer.
– The unit must only be used, maintained and repaired by personnel who are acquainted with it and have
been instructed about any potential danger.
– The manufacturer does not assume any liability for damage resulting from unauthorised modications to
the engine.
– Manipulation of the injection and control system may also affect the performance and exhaust-gas values
of the unit. Compliance with legal environmental regulations would then no longer be guaranteed.
– Should faults occur during operation, the cause must be determined and rectied immediately.
– Thoroughly clean the units prior to repair work and ensure that all openings where the ingress of dirt could
cause functional or safety issues, are sealed.
– Never run units dry, i.e. always make sure that they have been lled with lubricating oil before running them.
– Never run engines that have not been lled with coolant beforehand.
– Use a suitable information sign to clearly indicate units that are not ready to be operated.
– Use service products only in accordance with MAN service product recommendations; otherwise the
manufacturer's warranty is rendered void.
You can nd approved products on the Internet at: http://www.man-mn.com/ > Products & Solutions >
E-Business.
– Comply with the specied service intervals.
– Do not ll engine/gearbox oil above the maximum level mark. Do not exceed the maximum permitted
operational tilt.
– The special measures described in MAN Works Standard M 3069 Part 3 are necessary if buses/coaches
or trucks are to be withdrawn from service or held in storage for longer than 3 months.
3. Limited liability for spare parts and accessories
General
Please use only accessories approved by MAN Truck & Bus AG and MAN genuine parts for your MAN vehicle.
MAN Truck & Bus AG does not assume any liability for any other products.
4. Regulations for avoiding injury and environmental contamination
Health protection precautions

Avoid extended, excessive or repeated skin contact with service products, process materials, diluting agents
and solvents. Protect your skin using a suitable skin protection agent or protective gloves. Do not use any

INTRODUCTION
service products, process materials, diluting agents or solvents to clean your skin. Apply a moisturising skin
cream after cleaning your skin.
Service products and process materials

Do not use any containers intended for food or beverages to drain and store service products or process
materials. Please observe instructions issued by the relevant local authority on the disposal of service
products and process materials.
Coolant
Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority
when disposing of used coolant (mixture of antifreeze and water).
Cleaning the cooling circuit

Do not pour cleaning uids and rinsing water down the drain if this practice is restricted by specic local
regulations. However, the cleaning uid and rinsing water must, in all cases, be passed through an oil
separator with a sludge trap.
Cleaning the lter insert

When blowing compressed air through the lter insert, make sure the lter dust is collected by an extractor
system, or is blown into a dust collection bag. Otherwise, use a respiratory protection mask. Wear rubber
gloves or use a skin barrier hand cream when washing out the insert, because cleaning agents have
aggressive grease-dissolving characteristics.
Engine/gearbox oil, lter cartridges, inserts and box-type lters, desiccant cartridges
Filter inserts, cartridges and box-type lters (oil and fuel lters, desiccant cartridges for the air dryer) are
classied as hazardous waste materials. Please observe instructions issued by the relevant local authority
on the disposal of uids and process materials mentioned above.
Used engine/gearbox oil

Lengthy or repeated skin contact with any type of engine/gearbox oil removes grease from the skin. This
can cause dry skin, irritation or skin inammation. In addition to these hazards, used engine oil contains
hazardous materials which can cause dangerous skin diseases. It is particularly important to wear gloves
during an oil change.
Dealing with AdBlue®

AdBlue® is a synthetically produced 32.5% urea water solution used as an NOx reduction additive for diesel
engines with an SCR catalytic converter. AdBlue® is not a hazardous material. However, it disintegrates to
ammonium hydroxide and carbon dioxide during storage. For this reason, AdBlue® is classied in Germany
as water-polluting (WGK 1, water pollution class 1) and must not come in contact with waste water or seep
into the ground. Ensure good ventilation of the workplace when working on the AdBlue® system and do not
eat, drink or smoke. Avoid skin and eye contact with AdBlue®, thoroughly wash your hands and apply skin
protection agent before taking breaks or nishing work. In the event of skin contact with AdBlue®, rinse skin
with water and a skin cleaning agent and remove any soiled clothing immediately. Please seek medical advice
in the event of skin irritation. In the event of eye contact with AdBlue®, rinse eyes with water or eye rinsing
solution for a minimum of 10 minutes while keeping them open; remove contact lenses beforehand and seek
medical advice if the complaint persists. Immediately call for medical advice if AdBlue® has been swallowed.
Store AdBlue® containers in uid-tight collecting chambers at storage temperatures of no more than 25°C.
Absorb leaked or spilt AdBlue® with binding agents and dispose of this according to the regulations.
5. Information for working on the Common Rail system
General
– Fuel jets can cut through the skin. There is a re risk due to atomisation of the fuel.
– Never undo the bolt connections on the high fuel pressure side of the Common Rail system when the engine
is running (high-pressure line from the high-pressure pump to the rail, at the rail and on the cylinder head
to the fuel injector). When the engine is running, the lines are under a constant fuel pressure in excess of
1800 bar. Wait at least one minute before opening the bolt connections until the pressure has dropped.
Check pressure reduction on the rail with MAN-cats, if applicable.
– Do not remain in the vicinity of the engine when it is running.
– Do not touch live parts at the electrical connection of the fuel injectors when the engine is running.
– Any change to the original wiring may lead to the limit values of the heart pacemaker regulations being
exceeded, e.g. untwisted fuel injector wiring or insertion of a break box (terminal tester).

INTRODUCTION
– Vehicle operators and persons with heart pacemakers are not at risk from systems with MAN Common Rail
engines in approved operation.
– Fuel jets can cut through the skin. There is a re risk due to atomisation of the fuel.
– Never undo bolt connections on the high fuel pressure side of the Common Rail system when the engine
is running (fuel injection line from the high pressure pump to the rail, at the rail and on the cylinder head to
the fuel injector).
– Do not remain in the vicinity of the engine when it is running.
– When the engine is running, the lines are under a constant fuel pressure in excess of 1800 bar.
– Wait for at least one minute before undoing bolt connections to allow the pressure to drop.
– If necessary, check that the pressure has dropped in the rail with MAN-cats.
– Do not touch live parts at the electrical connection of the fuel injectors when the engine is running.
Information for people with pacemakers

– Any change in the original engine cabling may lead to the limit values of the heart pacemaker regulations
being exceeded, e.g. untwisted fuel injector cabling or insertion of a break box (terminal tester).
– There is no danger to the driver or any passengers with pacemakers, in approved operation.
– Vehicle operators with heart pacemakers are not at risk from systems with MAN Common Rail engines, in
approved operation.
– The product in original condition complies with all the currently known limit values for heart pacemakers.
Risk of damage due to ingress of dirt

– The components of the diesel fuel-injection system consist of high-precision parts that are subjected to
extreme loads. Due to the highly precise nature of this technology, all work on the fuel system requires the
highest possible degree of cleanliness.
– Even dirt particles over 0.2 mm can cause component failure.
Before starting work on the clean side

– Clean the engine and engine compartment while the fuel system is still closed off; when doing so, do not
use a powerful jet to clean the electrical components.
– Drive the vehicle into a clean area of the workshop in which no work is performed that could swirl up dust
(grinding or welding work, brake repairs, brake and power testing, etc.).
– Avoid air movements (possible swirling up of dust through starting of engines, workshop ventilation/heating,
draughts, etc.).
– The area of the fuel system that is still closed must be cleaned and dried by means of compressed air.
– Remove loose dirt particles such as paint akes and insulating material with a suitable suction device
(industrial vacuum cleaner).
– Cover areas of the engine compartment from which dirt particles could become detached, e.g. tilted cab,
engine compartment of bus engines, with new and clean foil covering sheets.
– Before starting disassembly, wash your hands and put on a clean working overall.
After opening the clean side

– It is not permitted to use compressed air for cleaning.
– Loose dirt must be removed during assembly work using a suitable suction device (industrial vacuum
cleaner).
– Only lint-free cleaning cloths are allowed to be used on the fuel system.
– Clean tools and working equipment before starting work.
– Only tools that are not damaged (e.g. cracked chromium plating) must be used.
– Materials such as cloths, cardboard or wood must not be used when removing and tting components, as
particles and bres may become detached from such materials.
– If paint akes should be produced when undoing connections (e.g. due to painting over the connections),
these must be carefully removed before the bolt connection is nally undone.
– The connection opening of all removed parts of the clean-side fuel system must be closed off immediately
with suitable caps.
– These sealing parts must remain packaged dust-tight until use and must be disposed of after being used
once.
– The components must then be stored carefully in a clean, closed container.
– Cleaning or test uids that have already been used must not be used for these components.
– New parts must only be taken out of the original packaging immediately before use.
– Work on removed components must be performed only at a work place equipped for this purpose.
– If removed parts are shipped, always use the original packaging of the new part.
When performing the work on bus/coach engines, it is essential that the following measures are also
observed:

INTRODUCTION
Risk of damage due to ingress of dirt

– Before opening the clean-side fuel system:
Clean the engine areas around the pressure sockets, fuel-injection lines, rail and cylinder head cover with
compressed air.
– Remove the cylinder head cover and then clean the engine areas around the pressure sockets, fuel-injection
lines and rail once again.
– First only loosen the pressure pipe sockets:
Loosen the pressure pipe socket union nuts and unscrew four turns.
Lift the pressure pipe sockets with a special tool.
Reason: only fully remove the pressure pipe sockets when the fuel injectors have already been dismantled
so that no dirt can fall into the fuel injectors from above.
– Remove the fuel injectors.
– After removal, rinse out the injectors with a cleaning uid, making sure that the high-pressure connection
hole is facing downwards.
– Remove the pressure pipe sockets; to do this, unscrew the pressure pipe socket union nut.
– Clean the injector bore in the cylinder head.
6. Limp-home program for units with electronic control units
General information
The units have an electronic control system that monitors itself (self-diagnostics) and the unit.
As soon as there is a malfunction, the malfunction is evaluated and one of the following measures is initiated:
– Output of a fault message with a diagnostic memory entry.

– Changeover to suitable, yet limited operation. Have malfunctions rectied by MAN Service immediately.
– The diagnostic memory entry is output directly in conjunction with MAN-cats.
7. Assembly information
Assembling pipes
– Pipes must not be mechanically deformed during assembly work; risk of fracture.
Mounting gaskets
– Only use MAN genuine gaskets
– Make sure that the areas to be sealed are undamaged and clean.
– Do not use adhesive agents or sealing agents. If necessary, to facilitate installation, use a little grease to
stick the seal to the part to be mounted.
– Tighten the bolts evenly to the specied tightening torque.
Mounting O-rings
– Only use MAN genuine O-rings.
– Make sure that the areas to be sealed are undamaged and clean.
Engine overhaul
– The engine's service life is inuenced by very different factors. For this reason, it is not possible to state
specic operating hours or mileage values for general overhauls.
– We are of the opinion that opening an engine or performing a general overhaul is not required, as long as
the engine has good compression values and the following operating values do not deviate considerably
from those determined at start-up.
– Charging pressure
– Exhaust gas temperature
– Coolant and lubricating oil temperatures
– Oil pressure and oil consumption
– Smoke behaviour
The following criteria have considerable inuence on the engine's service life:
– Correct performance setting according to deployment
– Correct installation
– Approval of the installation by authorised personnel
– Regular maintenance according to the maintenance record

INTRODUCTION
TYPE OVERVIEW
System description T 160 (1.) Power Train Manager (PTM) applies to the vehicles listed below.
Note: This list is not intended to be exhaustive.
Trucknology Generation S (01S - 99S, 01M - 99M, 01W - 99W)
Type Model designation Type Model designation

03S TGS 18.D20/D26 4X2 BB 45S TGS 24.D20/D26 6X2-2 LL-U
06S TGS 18.D20/D26 4X2 BL 49S TGS 32.D20/D26 8X4 BB
08S TGS 18.D20/D26 4X2 BL-TS 52S TGS 18.D20/D26 4X4 BB
10S TGS 18.D20/D26 4X2 LL 56S TGS 26/33.D20/D26 6X6 BB
13S TGS 18.D20/D26 4X2 LLS-U 59S TGS 35.D20/D26 8X6H BL
15S TGS 18.D20/D26 4X2 LL-U 70S TGS 26/33.D20/D26 6X6H BL
18S TGS 26.D20/D26 6X2-2, 6X2-4 BL 71S TGS 28.D20 6X4H-4 BL
21S TGS 26.D20/D26 6X2-2, 6X2-4 LL 73S TGS 35.D20/D26 8X4H-4, 8X4H-6 BL
22S TGS 18.D20/D26 4X4 H BL 74S TGS 28.D20 6X2-4 BL
24S TGS 26.D20/D26 6X2/2, 6X2/4 BL 80S TGS 18.D20/D26 4X4 BL
26S TGS 26/33.D20/D26 6X4 BB 82S TGS 26/33.D20/D26 6X6 BL
30S TGS 26/33.D20/D26 6X4 BL 84S TGS 28.D20/D26 6X4-4 BL
35S TGS 26.D20/D26 6X4H-2, 6X4H-4 BL 89S TGS 28.D20/D26 6X2-2 BL
37S TGS 35.D20/D26 8X4 BB 90S TGS 35.D20/D26 8X2-4, 8X2-6 BL
39S TGS 41.D20/D26 8X4 BB 92S TGS 35.D20/D26 8X4-4 BL
41S TGS 32/35.D20/D26 8X4 BL 93S TGS 35/41.D20/D26 8X6 BB
42S TGS 26.D20/D26 6X4H/2, 6X4H/4 BL 96S TGS 35/41.D20/D26 8X8 BB

01M TGS 18.D20/D26 4X4 BB-MIL 03M TGS 40.D20/D26 6X6 BB-MIL
02M TGS 26.D20/D26 6X6 BB-MIL 04M TGS 35.D20/D26 8X8 BB-MIL

03W TGS 19 4X2 BBS-WW 58W TGS 40 6X6 BB-WW
06W TGS 19 4X2 BLS-WW 60W TGS 35/41 8X8 BB-WW
18W TGS 26 6X2-2, 6X2-4 BL-WW 71W TGS 19 4X2 BBS-WW-CKD
19W TGS 28 6X2-2 BL-WW 72W TGS 19 4X2 BLS-WW-CKD
26W TGS 33 6X4 BB-WW 76W TGS 33 6X4 BB-WW-CKD
30W TGS 26/33 6X4 BLS-WW 77W TGS 40 6X4 BB-WW-CKD
34W TGS 40 6X4 BB-WW 78W TGS 26 6X4 BL-WW-CKD
39W TGS 41 8X4 BB-WW 79W TGS 41 8X4 BB-WW-CKD
52W TGS 18 4X4 BB-WW
56W TGS 33 6X6 BB-WW
Trucknology Generation X (01X - 99X)

05X TGX 18.D20/D26 4X2 BLS 30X TGX 26/33.D20/D26 6X4 BL

INTRODUCTION
06X TGX 18.D20/D26 4X2 BL 42X TGX 26.D20/D26 6X4H/2, 6X4H/4 BL

10X TGX 18.D20/D26 4X2 LL 45X TGX 24.D20/D26 6X2-2 LL-U
13X TGX 18.D20/D26 4X2 LLS-U 78X TGX 18.V8 4X2 BLS
15X TGX 18.D20/D26 4X2 LL-U 79X TGX 33.V8 6X4 BL
18X TGX 26.D20/D26 6X2-2, 6X2-4 BL 86X TGX 41.D26 8X4/4 BBS
21X TGX 26.D20/D26 6X2-2, 6X2-4 LL 87X TGX 41.D26 8X4/4 BLS
22X TGX 18.D20/D26 4X4H BL 88X TGX 28 6X2-2 BL-CKDL
24X TGX 26.D20/D26 6X2/2, 6X2/4 BL 89X TGX 28.D20/D26 6X2-2 BL
26X TGX 26/33.D20/D26 6X4 BB 92X TGX 35.D20/D26 8X4-4 BL
27X TGX 28 6X4 BB 94X TGX 41.V8 8X4/4 BBS
28X TGX 28 6X4 BB-CKD 95X TGX 41.V8 8X4/4 BLS
OPERATING INSTRUCTIONS FOR CIRCUIT DIAGRAMS

INTRODUCTION
(1) Electrical component designation (5) Cable designation, numbers in brackets

(example – diode V100 on the central are printed conductors of a printed circuit
electrical system, position 53) board
(2) Installation location on the front of the (6) Line disconnection and line continuation
central electrical system (here - embossed with sheet number (sheet 2) and path
position number 53) number (path 4)
(3) Plug connector on the back of the (7) Plug connector (example – single-pin plug
central electrical system (here – plug connector X104)
78, connection 8) (8) Indication of installation location of
(4) Cable number, abbrev. of colour component (see - installation location
designation if cable is coloured, identiers)
cross-section stated only if not equal (9) Current path (numbered from 1 up to 55/60
to 1² for each plan)
Installation locations for location designations
Installation locations for left-hand drive vehicles (TG)
(A) Rear (B2) Gearbox

(B1) Engine (C) Front

INTRODUCTION
(C1) Bumper
(C2) Step unit, right
(C3) Step unit, left
(E6) Central electrical system area
(E7) Control unit plug-in modules
(E8) Cab rear wall
(F) Instrument panel
(F1) Middle section
(F2) Steering column/steering wheel
(F3) Pedals
(F4) Front wall, inside left
(F5) Front wall, inside right
(F6) Driver's seat
(F7) Co-driver's seat
(F8) Gearshift console
(G) Battery box
(H1) B-pillar, driver's side
(H2) A-pillar, driver's side
(J1) B-pillar, co-driver's side
(J2) A-pillar, co-driver's side
(L) Ceiling/roof
(N) Front axle
(P) Rear axle
(R1) Frame, front part
(R2) Frame, rear part
(S1) Door, left
(S2) Door, right

INTRODUCTION
Installation locations for right-hand drive vehicles (TG)
(A) Rear (G) Battery box

(B1) Engine (H1) B-pillar, co-driver's side
(B2) Gearbox (H2) A-pillar, co-driver's side
(C) Front (J1) B-pillar, driver's side
(C1) Bumper (J2) A-pillar, driver's side
(C2) Step unit, right (L) Ceiling/roof
(C3) Step unit, left (N) Front axle
(E6) Central electrical system area (P) Rear axle
(E7) Control unit plug-in modules (R1) Frame, front part
(E8) Cab rear wall (R2) Frame, rear part
(F) Instrument panel (S1) Door, left
(F1) Middle section (S2) Door, right
(F2) Steering column/steering wheel
(F3) Pedals
(F4) Front wall, inside left
(F5) Front wall, inside right
(F6) Co-driver's seat
(F7) Driver's seat
(F8) Gearshift console

DEVICE DESCRIPTION
DEVICE DESCRIPTION
SYSTEM DESCRIPTION
General
The Power Train Manager (A1124) replaces the vehicle management computer (A403) that was used
previously. The management variables for the control units in the driveline are specied by the Power Train
Manager as a primary control unit. The trend data is recorded and service intervals calculated via the Power
Train Manager (A1124), which has the same features as the vehicle management computer.
Vehicles with an automatic gearbox have a different Power Train Manager (A1124) than the one tted to
vehicles with a manually operated gearbox.
The differences compared with the vehicle management computer (A403) are:
– The electrical connections and the connectors

– A more powerful processor
– A larger memory
Note: It is not possible to convert from the vehicle management computer (A403) to the Power Train Manager
(A1124) and vice-versa. Please observe SI 367102.
The diagram below shows part of the signal and bus structure for the control and display functions of the
Power Train Manager (A1124):
(A) Input signals (3) (Q101) Steering wheel lock

(B) Output signals (4) (A943) Multi-function steering wheel
(LIN) Local Interconnect Network (5) (B269) Temperature sensor for outside air
(M-CAN) Engine control CAN data bus (6) (A302) Central on-board computer 2
(T-CAN) Driveline CAN data bus (7) (A143) ECAS control unit
(1) (A1124) Power Train Manager (8) (A144) Retarder control unit
(2) (A477) Electronic immobiliser

DEVICE DESCRIPTION
(9) (A330) TipMatic AS-Tronic gearbox (11) (Y281) Solenoid valve for engine brake
control unit (12) (A968) Fan clutch with speed sensor
(10) (Y307) Valve block (13) (A435) EDC control unit
Interfaces to other systems

The system communicates with the control unit using a data bus. See “CAN data bus system structure” for a
control unit diagram. A fault in or a failure of a system (e.g. EBS, EDC, ECAS, etc.) is notied to the central
on-board computer 2 via the driveline CAN data bus. If there is no anticipated and regular CAN message,
the system detects a timeout fault and displays it.
Example: a control unit fails completely and no longer takes part in communication. The central on-board
computer 2 sends the signal to the combined instrument via the combined instrument CAN data bus. The
fault is displayed on the combined instrument using check lamps, symbols and texts.
CAN data bus system structure
TGS/TGX
(A143) ECAS control unit (A407) Combined instrument

(A250) Air-conditioning system/auxiliary (A408) Tachograph with terminating resistor,
air-conditioning system control unit combined instrument CAN
(A266) Converter-clutch unit/retarder control unit (A435) EDC control unit with terminating resistors,
(A302) Central on-board computer 2 (ZBR2) with engine CAN and HD OBD CAN
terminating resistor, combined instrument (A479) ACC control unit
CAN (A564) Radio/CD player
(A312) Customer-specic control module with (A577) On-board telematics module
terminating resistor, body CAN (A609) LGS control unit
(A330) TipMatic control unit (on gearbox) with (A626) Hydrostatic front-wheel drive control unit
terminating resistor, driveline CAN (A808) Denoxtronic supply module with
(A384) Rear-axle steering control unit (RAS-EC) terminating resistor, HD OBD CAN
(A402) EBS control unit

DEVICE DESCRIPTION
(A1124) Power Train Manager with terminating

resistors, engine CAN and driveline CAN
(A...) Other systems can be networked
(AB) Body manufacturer electronics on CAN
connection, e.g. FMS systems
(A-CAN) Body manufacturer CAN data bus
(simultaneously connection for FMS
interface)
(X200) Diagnostics plug connector
(H-CAN) Highline CAN data bus
(HDOBD)Heavy Duty On-Board Diagnosis CAN
data bus
(I-CAN) Combined instrument CAN data bus
(M-CAN) Engine control CAN data bus
(T-CAN) Driveline CAN data bus

DEVICE DESCRIPTION
FUNCTIONAL DESCRIPTION

The operating voltage of the Power Train Manager is 24 V. The power supply comes from the central electrical
system (A100).
The Power Train Manager (A1124) is protected by two fuses:
– F1026, fuse for PTM, terminal 30 (battery)

– F1027, fuse for PTM, terminal 15 (ignition)
Top
(1) Cooling surface
The cooling surface must be free of adhesive labels.
Bottom with drain bores
Functions
– Cooling
– Engine warming
– Cruise control/maximum speed control
– Intermediate speed control
– Power take-offs
– Saving data
– Trend data
– Maintenance data
The driveline CAN data bus (T-CAN) links the Power Train Manager (A1124) to the control units for the brakes,
gearbox, air suspension, retarder, central on-board computer etc. The Power Train Manager is connected to
the EDC control unit via the engine CAN data bus (M-CAN). The Power Train Manager is connected to the
multi-function steering wheel, DNR switch or stalk switch via the LIN data bus.

DEVICE DESCRIPTION
Various switches, sensors and actuators are connected for other functions on the Power Train Manager.
The Power Train Manager (A1124) is EOL-programmed (End of Line). At the end of the line, the vehicle
manufacturer inputs vehicle-specic parameters alongside the already entered system manufacturer
parameters. The entered parameters can be checked – or changed if necessary – using MAN-cats® II.
The diagnostic codes stored in the diagnostic memory of the Power Train Manager are read out via the 16-pin
HD-OBD X200 diagnostic socket using MAN-cats® II.
There are 10 holes to drain away condensation on the bottom of the Power Train Manager. At least one drain
bore must be open so that the condensation can drain away. The Power Train Manager is therefore installed
horizontally.
(1) Drain bores
MAN-cats® II
After selecting “Main menu”, select the menu item “Central computer / instrumentation” and then the
system type “FFR/PTM/MFR”. Then, under “Selection menu diagnosis PTM”, select the item “Control unit
identication”.
All important control unit and vehicle data can be found under this menu item.
The diagnostic memory is always rst read out.
Plug assignment
Plug connector supply, VS
In
Pin Line no. H/L Designation
/Out
1 31000 L I Ground
2 —– —– —– not used
3 60044 H I Power supply to terminal 15

DEVICE DESCRIPTION
In
/Out
4-5 —– —– —– not used
6 60027 H I Fuse F371, terminal 30
H means high and L means low
Plug connector A
In
/Out
1 —– —– —– not used
2 60353 H O Valve block for low splitter box
3 60633 H O Valve block for comfort split
4 - 13 —– —– —– not used
14 60354 H I Valve block for high splitter box
15 -
—– —– —– not used
16
17 31050 L O Ground clutch servo
18 -
19
20 40329 H O Solenoid valve for PTO 1
21 40330 H O Solenoid valve for PTO 2
22 -
25
26 60372 H O Valve block for gate lock (single-H)
27 60370 H O Valve block for low range (single-H)
28 31025 L O Ground for single-H valve block
29 31023 L O Ground for split valve block
30 -
38
39 60371 H O Valve block for range-change group (single-H)
40 -
48
Plug connector B
In
/Out
1-3 —– —– —– not used
4 185 H I/O Diagnosis CAN data bus, high signal
5 159 H I/O Engine CAN data bus, high signal
6 blue/red H I/O Driveline CAN data bus, high signal
7 —– —– —– not used
8 60614 H I Gearbox input speed
9 16129 H I Oil level sensor, positive

DEVICE DESCRIPTION
In
/Out
10 60146 H I Pedal-travel sensor 2
11 31017 L O Ground, ambient temperature
12 —– —– —– not used
13 43012 H O Supply to EVBec module
14 -
15
16 186 L I/O Diagnosis CAN data bus, low signal
17 160 L I/O Engine CAN data bus, low signal
18 blue/white L I/O Driveline CAN data bus, low signal
19 -
20
21 blue H I Exhaust gas back pressure sensor signal
22 60143 L O Clutch displacement sensor
23 60614 L O Fan clutch speed sensor (-)
24 —– —– —– not used
25 61104 H O Supply, fan clutch hall switch (+)
26 -
30
31 99125 H I Immobiliser
32 —– —– —– not used
33 16138 H I Temperature sensor - engine oil temperature
34 60142 H I Clutch displacement sensor
35 60613 L O Gearbox input speed (+)
36 31016 L O Ground for analogue inputs (-)
37 43329 H O Solenoid valve for engine brake
38 61304 H O Fan clutch
39 64515 —– I/O LIN DNR switch
40 —– —– —– not used
LIN, PTM - multi-function steering wheel - stalk switch - combined
41 64512 —– I/O
instrument
42 —– —– —– not used
43 61305 H I Hall switch signal, fan clutch
44 —– —– —– not used
45 60145 H I Pedal-travel sensor 1
46 brown L O Ground, exhaust gas back pressure sensor
47 31027 L O Ground, oil level sensor
48 —– —– —– not used

DEVICE DESCRIPTION
Plug connector C
In
/Out
1 60147 H I Ambient temperature sensor
2-3 —– —– —– not used
4 40631 H I Off-road gear engaged
5-6 —– —– —– not used
7 50320 H I Request, external engine start
8 40142 H I Check lamp, PTO 2
9 —– —– —– not used
10 43568 H I Engine brake switch
11 —– —– —– not used
12 60632 H I Button for comfort split
13 —– —– —– not used
14 60634 H I Switch, single-H
15 -
16
17 50300 H I Engine start request (terminal 50)
18 —– —– —– not used
19 43315 H I Button, engine stop
20 16109 H I Parking brake check pressure switch - relay K
21 60606 H I Switch, splitter box request
22 —– —– —– not used
Intermediate speed control (ZDR) 1 request as well as ZDR 3, 5, and
23 60525 H I
7 in combination with pin C35 and C47 (binary coding)
24 -
25
Maximum speed limitation (HGB) request via resistor group R134
26 60523 H I
(HGB in 3 stages)
27 -
30
31 40354 H I Power take-off 1 - request
32 —– —– —– not used
33 60665 H I Comfort Shift button
34 60610 H I Intelligent linking
35 60526 H I
36 —– —– —– not used
Torque speed limitation (MDB) request via resistor group R134 (MDB
37 60524 H I
in 3 stages)
38 -
42
43 40355 H I Power take-off 2 - request
44 40141 H I PTO1 status (feedback, power take-off 1 active)
45 —– —– —– not used

DEVICE DESCRIPTION
In
/Out
46 60521 H I Cruise control/road speed limiter switch
47 60641 H I
48 60144 H I Gearbox limit switch, neutral
Technical data:
Operating voltage: 16 - 32 V
Overvoltage: 36 V/1 hour at 40°C ambient temperature
Nominal voltage: 24 V
Test voltage: 27.6 V
Maximum power consumption at terminal 30: 10 A
Maximum power consumption at terminal 15: 2A
Repair instructions
– Removing and tting the control unit
Parametrisation is not required if an existing Power Train Manager needs to be removed and tted.
– Replacing the control unit
If the Power Train Manager is replaced, the Power Train Manager needs to be parametrised.
– Parameterising the control unit
Parametrisation is also required if the Power Train Manager was not parametrised correctly.

DEVICE DESCRIPTION
Pedal unit
The pedal unit is a pre-assembled and tested unit and supports the following on the base plate:
– The accelerator (A410) with non-contact sensors

– The brake pedal with service brake valve
– The clutch pedal with clutch master cylinder/clutch servo.
The entire unit is inserted into the vehicle front wall from the front, sealing off the front wall. The hydraulic line
connections on the clutch master cylinder/clutch servo and the compressed-air connections on the service
brake valve are arranged in front of the front wall. The electrical connections for the cab cable harness are
located on the inside of the pedal unit.
MAN-cats® II:
After selecting “Selection menu monitoring”, select the “Pedal unit” menu item. In this menu item you can
check the various pedal functions.
Accelerator (A410)
Accelerator description
A steel spring is tted in the accelerator in order to generate the accelerator forces.
Feedback on the accelerator position is provided by means of two non-contact hall sensors. Two internal
electronic circuits convert the analogue signals into two PWM signals. The output PWM signals indicate the
current accelerator position. The PWM signals are displayed graphically on the MAN-cats® II screen.
The PWM values of the mechanical stops are stored as parameters in the ash memory of the Power Train
Manager (A1124) – this applies to both PWM signals. The accelerator position is standardised between the
mechanical stops based on PWM1. In the event of a fault, PWM2 is used.
If an accelerator fault occurs, a parametrisable engine speed and torque limiter is activated.
In conjunction with the current engine speed, the accelerator pedal map is used to determine the accelerator
pedal torque characteristic map between idling-speed position and full-load position.
The “Idling speed” and “Kickdown” signals are determined based on the standardised accelerator position.
If the accelerator position is below the closed-throttle (idle) threshold, active idling is detected. If it is above
the threshold, the accelerator pedal torque is output. This reaches 100% (90%) at the parametrised full-load
point. If the accelerator is pressed beyond this point (and exceeds the threshold for kickdown), the kickdown
function is activated. This threshold has a hysteresis. The function is deactivated as soon as the accelerator
position is below the full-load threshold.
The accelerator position is checked for plausibility in conjunction with the brake pedal information. If the
accelerator position is above the idling speed point when the brakes are applied, the current accelerator
position is taken as the idling value. As soon as the accelerator position falls back below this value, the idling
value is corrected so that it is once again equal to the calibrated value in the Power Train Manager ash
memory.

DEVICE DESCRIPTION
In order to enable the brakes to be applied when moving off on a hill, for example, the value is queried only
if the accelerator is pressed before the brake pedal. However, a fault is only entered in the Power Train
Manager's diagnostic memory if the closed-throttle (idle) position is not reached on 5 occasions.
Plug assignment
Plug connector: 8-pin/coding A
Pin Line no. Assignment

1 —– not used
2 60145 PTM control unit - pedal-travel sensor 1
3 15014 Fuse - power supply to terminal 15
4 31000 Ground
5 31000 Ground
Power supply to terminal 15 - vehicle management computer/PTM
6 60028
control unit
7 60146 PTM control unit - pedal-travel sensor 2
8 —– not used
Technical data
Power supply: 10 - 32 V
Overvoltage: 36 V for max. 1 hour
Power requirement during operation:

Maximum current: < 15 mA at 32 V
Minimum current: > 5 mA at 10 V
All inputs and outputs as well as the PWM signal lines are short-circuit-proof and protected against polarity
reversal.

DEVICE DESCRIPTION
Accelerator working areas
(1) Idling speed stop (3) Kickdown

(2) Full load (load point) (4) Full lock
Idling speed stop PWM1 Pedal angle 0° PWM 18 - 29% duty factor
Idling speed stop PWM2 Pedal angle 0° PWM 82 - 71 % duty factor
Full lock PWM1 Pedal angle 20° PWM 32 - 15 % duty factor
Full lock PWM2 Pedal angle 20° PWM 68 - 85 % duty factor
Adjustment range: 20° 52% duty factor (setpoint value)
Load point: 5° before full lock 13% duty factor before full lock
Kickdown force increase: 3.25° before full lock
Measurement of kickdown
force (controller-side kickdown 1.6° before full lock 4.16 % duty factor before full lock
evaluation)
Important
The accelerator can only be fully depressed by forcefully pressing the accelerator and reaching a hard
mechanical full lock (including kickdown).
An oscilloscope can be used to see the duty factor and the opposing paths of PWM signals.
Oscilloscope display for PWM1
(1) Accelerator (A410) not pressed (3) Accelerator (A410) fully pressed
(2) Accelerator (A410) partially pressed
Oscilloscope display for PWM2

DEVICE DESCRIPTION
In MAN-cats® II, you can see the PWM1 and PWM2 signals concurrently (see gure).
(1) PWM 1 pedal unit (3) Accelerator position

(2) PWM 2 pedal unit
Repair instructions
– Removing/tting, replacing an accelerator
If an existing accelerator needs to be removed and tted, it does not need to be calibrated.
Clutch pedal
Clutch functional test

The function of the clutch is checked using MAN-cats® II. Under “Selection menu diagnosis PTM”, select the
“Clutch function test” item.
The disengage point and/or biting point of the clutch is/are determined in the “Clutch disengage point/biting
point” window. This information is used to determine the cause of noises that occur when shifting gears.
Calibration
To calibrate the clutch travel, the system needs to be bled.
The calibration and/or adjustment of the clutch pedal is carried out using MAN-cats® II. After selecting the
“Selection menu diagnosis PTM” select the “Calibration” menu item.
There are two ways of calibrating the clutch pedal.
– Clutch pedal calibration with replacement of lining

– Clutch pedal calibration without replacement of lining
The “Clutch pedal adjustment” window is automatically displayed after selecting “Clutch pedal calibration with
replacement of lining”. This is used to determine the full locks of the clutch pedal when it is fully depressed.

DEVICE DESCRIPTION
Keep the pedal in this position for around 3 seconds, then release the clutch pedal. Repeat this process two
or three times until there is no change in the full locks.
The values determined during calibration (minimum and maximum) must be saved. Next, turn the ignition off.
The values are saved; then turn the ignition back on again. The clutch pedal is calibrated.

DEVICE DESCRIPTION

The fan clutch with speed sensor (1) provides cooling as required and thus helps to prevent the risk of the
engine overheating.
If the load on the engine is small, the headwind owing through the radiator is sufcient to keep the coolant
temperature in the optimum range. This means that the fan clutch only operates at low speed, i.e. the engine
rotates faster than the fan clutch.
As the load on the engine increases, e.g. when driving uphill or with a trailer, the temperature in the engine
compartment and thus also the coolant temperature increases signicantly. The fan clutch then operates at
full speed.
The Power Train Manager activates a solenoid valve in the fan using a PWM signal. The speed sensor in the
fan returns a signal to the Power Train Manager.
Note:
If the supply voltage fails, the fan clutch is fully activated, i.e. the engine cannot overheat as the fan is
operating at maximum possible speed.
Function:
24 V voltage activates solenoid which attracts armature plate. Valve spring closes hole and fan clutch is
deactivated. Zero voltage deactivates solenoid, armature plate returns to starting position. Valve spring
opens hole and fan clutch is activated.
In conjunction with the PWM signal, the fan speed is therefore continuously variable.
The fan speed depends on the following:
– Coolant temperature
– Ambient temperature
– Charge-air temperature
– Secondary retarder or PriTarder
Checking the fan clutch function using MAN-cats® II:

After selecting the “Selection menu monitoring”, select the “Fan control” menu item. Under this menu item
you can check the speed of the fan clutch and the fan control. You can simulate the fan clutch actuation in
the “Actuator test” menu item.
The function of the fan clutch should be checked when the engine is running. Otherwise, it will not be possible
to check the speed control. Since this relates to a speed-controlled fan clutch (type of actuation: controlled),
the main fan speed must be valid when the engine is running. If this is the case, the fan clutch is working
properly. If this is not the case, there is a fault at the speed sensor.

DEVICE DESCRIPTION
Technical data:
Current consumption: Minimum current at a voltage of 20 V Imin = 0.6 A
Maximum current at a voltage of 32 V Imax = 1.2 A
Typical current at a voltage of 28 V Itype = 0.9 A
Resistance: Minimum resistance at a voltage of 20 V Rmin = 27 Ω
Maximum resistance at a voltage of 32 V Rmax = 33 Ω
Typical resistance at a voltage of 28 V Rtype = 30 Ω
Frequency: Minimum frequency at a voltage of 20 V fmin = 1 Hz
Maximum frequency at a voltage of 32 V fmax = 12 Hz
Typical frequency at a voltage of 28 V ftype = 10 Hz
Power output 26 W
Plug assignment
Plug connector: orange

1 61304 Fan clutch
2 31000 Ground
3 61104 Supply, fan clutch hall switch
4 61305 Hall switch signal, fan clutch
5 60614 Fan clutch hall switch (-)
6 —– not used
Repair instructions
– Removing and tting a fan clutch with speed sensor
See section “Removing and tting the fan clutch” in the repair manual.
– Replacing a fan clutch with speed sensor
See section “Removing and tting the fan clutch” in the repair manual.

DEVICE DESCRIPTION

The multi-function steering wheel allows the driver to operate the cruise control and maximum speed control,
as well as the radio/CD player, without taking his/her hands off the steering wheel.
(1-5) Cruise control/road speed limiter (6-10) Menu operations
Buttons 6-10 can be used to call up and operate the different menus, which are called: Vehicle menu, Audio
and Telephone. Buttons (1-5) are used for the cruise control and road speed limiter.
See the Operator's Manual for instructions on how to use the multi-function steering wheel (A943).
MAN-cats® II:
After selecting the “Selection menu monitoring”, select the “Multi-function steering wheel (MFL)” menu item.
Under this menu item you can check the multi-function steering wheel by pressing a button on the steering
wheel and checking under Monitoring whether the corresponding display has changed.
Technical data:
Overvoltage: 36 V/1 hour at 40°C ambient temperature
min. current at a voltage of 16 V: 3 mA (lighting only)
max. current at a voltage of 32 V: 7 mA (lighting only)
Plug assignment

DEVICE DESCRIPTION

Power supply to terminal 15 - vehicle management computer/PTM control
1 60028
unit
2 31000 Ground
LIN, vehicle management computer/PTM - multi-function steering wheel
3 64512
- stalk switch - combined instrument
Repair instructions
– Removing and tting a multi-function steering wheel (MFL)
See the “Removing and tting the steering wheel” section in the repair manual.
– Replacing the multi-function steering wheel (MFL)
See the “Removing and tting the steering wheel” section in the repair manual.

DEVICE DESCRIPTION
LIN data bus

The LIN (Local Interconnect Network) data bus is a single-wire bus with 24 V vehicle electrical system level.
The network contains a single master (Power Train Manager) and several slaves. Communication is based
on a serial data format (data rate 9.6 kBit/s). The LIN protocol is a serial communication protocol.
System structure with multi-function steering wheel
Master Line no. Slave

Power Train Manager (A1124) 64512 Stalk switch for retarder/gearbox (A942)
Combined instrument (A407)
System structure without multi-function steering wheel

DEVICE DESCRIPTION

Continuous brake tip switch (A437)
Stalk switch for cruise control/gearbox
Power Train Manager (A1124) 64512
(A429)
Combined instrument (A407)
System structure for gearbox DNR switch

Power Train Manager (A1124) 64515 Gearbox DNR switch (A434)

DEVICE DESCRIPTION
DESCRIPTION OF COMPONENTS
Installation location
The Power Train Manager (1) is located next to the central electrical system in the control unit holder on the
co-driver's side (remove device cover).

DEVICE DESCRIPTION
Accelerator (A410)
The accelerator (1) is the pedal on the right (shown without front wall cover).

DEVICE DESCRIPTION
The fan clutch with speed sensor (1) is located at the front of the engine.

DEVICE DESCRIPTION
Installation of multi-function steering wheel A943 (TGS/TGX)

DEVICE DESCRIPTION
DIAGNOSTICS
General
Most control units that can be tested using MAN-cats® II are connected with diagnostic socket X200 pin 3/4
via a communication line. The diagnostic system stimulates a specic control unit via the communication line.
The control unit responds and transmits the faults stored in its diagnostic memory via the communication line
in digital code.
Control units that are addressed via the driveline CAN and thus no longer have a communication line, such
as TBM, ECAS2 or EBS, are addressed via the diagnosis CAN of the PTM. In this case, the PTM acts as a
gateway.
Diagnostic socket HD-OBD (X200)

The SPN diagnostic codes can be read out from the diagnostic memory of various control units using
MAN-cats® II (connection to diagnostic socket X200). The results are displayed on the MAN-cats® II display.
The 16-pin diagnostic socket HD-OBD according to ISO 15031-3 replaces the former 12-pin MAN diagnostic
socket. HD-OBD stands for Heavy Duty On-Board Diagnosis. Heavy duty in this case refers to heavy
commercial vehicles.
In future, this OBD standardisation will make it possible for the rst time for almost all vehicles worldwide to
have a uniform diagnostic system for exhaust-relevant components.
Plug assignment table
Pin Line Function

1 59101 Speed signal, alternator, terminal W
2 —- not used
3 16202 Communication line
4 31000 Ground, terminal 31
5 —- not used
6 185 HD-OBD CAN high
7 —- not used
8 16000 Power supply to terminal 15
9 - 13 —- not used
14 186 HD-OBD CAN low
15 —- not used
16 30009 Power supply to terminal 30

DEVICE DESCRIPTION
Installation location of diagnostic socket
Diagnostic socket HD-OBD (X200) for TGS/TGX
The diagnostic socket HD-OBD X200, 16-pin (1) is located on the co-driver's side under a cover, which has
to be folded down. The central electrical system is located above the socket.
Main functions of the diagnostics

– Fault detection
– Fault analysis
Occurrence
Meaning
Identication
Fault type (static, sporadic, etc.)
– Fault storage
– Simulation for troubleshooting
Malfunction indicators
The electronic control unit has self-diagnosis functions for all outputs and various inputs. The faults at the
inputs and outputs, as well as internal faults, are detected, analysed and stored in the control unit diagnostic
memory.
The faults are also indicated on the combined instrument display and/or by the central warning lamp (H111)
in conjunction with the check lamp of the corresponding system.
In the case of STOP commands, the word STOP also appears on the display and the central warning lamp
(H111) ashes RED at 1-second intervals.
The central warning lamp (H111) lights up:

– YELLOW to indicate either a function or a warning
– RED to indicate a fault
The red warning lamp has priority over a yellow warning lamp. Functions or warnings (YELLOW) are always
overridden by malfunctions (RED).
In the event of a CAN failure (combined instrument – central on-board computer), the central warning lamp
(H111) lights up RED.
All current malfunction indicators are available when the ignition is switched ON (terminal 15), irrespective of
the vehicle status.
The faults diagnosed and stored in the control unit may involve different risks. Therefore, each individual fault
is assigned a priority.

DEVICE DESCRIPTION
Status display, FMI (Failure Mode Identication)
FMI 12 Disconnection or
FMI 0 Fault not specied FMI 6 Short-circuit to +UBat
short-circuit to +UBat
FMI 1 Too high FMI 13 Disconnection or

FMI 7 Short-circuit
short-circuit to ground
Memory status
FMI 2 Too low FMI 8 Signal faulty

FMI No fault
FMI 3 Implausible FMI 9 Device fault FMI Fault stored
FMI 4 No signal available FMI 10 Disconnection FMI Intermittent fault
FMI 5 Short-circuit to ground FMI 11 Loose contact FMI Fault active and has been
stored
Priority in the display/diagnosis, software versions R22 and R24
Colour of central
Symbol Indicator meaning Diagnostics meaning
warning lamp (H111)
Threat of vehicle damage. Driving

Safety Red ashing
safety at risk.
Workshop visit necessary

Workshop Illuminated red immediately. Driving safety may
be at risk.
Remedy the fault immediately

or drive slowly to a workshop,
Information Illuminated yellow
depending on the cause of the yellow
message.
For display of fault texts, see system description of combined instrument T 62.

DEVICE DESCRIPTION
Structure of the fault texts in the diagnostic message
The fault text message structure always includes:

– Symbol
– Text message
– Check lamp
– Audible signal
There are 3 types of text message:

– One message
– Several messages
– Message indicating a value
One message
In the case of a single message, only the fault, system name and priority are indicated.
Several messages with multi-function steering wheel A943
(1) Display for several faults (3) Symbol for scrolling

(2) Symbol for conrmation (4) Symbol for at least 10 faults
If there are several faults, this can be seen by the double left edge (1). If more than 9 faults occur, this is
indicated by the plus sign (4) in the status line.

DEVICE DESCRIPTION
Several messages without multi-function steering wheel A943
The double edge indicates that there are several messages, while the two lower rectangular elds indicate
the possible button functions for the buttons shown on the next graphic.
Message indicating a value
The combined message shows precisely the rear axle and side on which the tyre with insufcient pressure is
located. The values allow a comparison. The incorrect value has a black background.

DEVICE DESCRIPTION
SPN diagnostic codes shown on the display, software versions R22 and R24
The display is integrated in the combined instrument (A407). All the driver and service information is displayed.
View of the display
The gure above shows a fault message from the ACC system. If you now call up the diagnostics in the
menu, you will see the SPN diagnostic code on the display, as shown by the next illustration.
The fault is active and has a priority of 5. The SPN is 02201 and the FMI (Failure Mode Identication) is 3
(specic fault text message).
Break box
The break box is used to check the functioning of all the Power Train Manager components in installed state.
Components:

DEVICE DESCRIPTION
Position Designation Item number

1 Break box with measuring jumpers 80.99641-6027
The set of cable arms 48 + 6 = 54-pin A+B for the PTM control unit consists of
items 2, 3 and 4, which are described below. The components included in the 80.99641-6036
set can also be ordered individually at a later date.
2 Cover plate for break box, 54-pin 80.99641-0029
3 Cable arms, 54-pin (pin) for connection to the vehicle cable harness 80.99641-0028
4 Cable arms, 54-pin (socket) for connection to the control unit 80.99641-0027
Connecting the break box:

– Secure the vehicle to prevent it from rolling away unintentionally (parking brake, wheel chocks).
– Switch off the engine and the ignition.
– Check that the Power Train Manager is protected by the prescribed fuses F1027 - PTM (terminal 15) with
7.5 A and F1026 - PTM (terminal 30) with 10 A.
– Disconnect the Power Train Manager.
– Connect the break box between the Power Train Manager and the vehicle cable harness.
The test step list allows you to check the components and/or functions of the Power Train Manager using the
break box and a multi-function measuring device (multimeter).
Sensor signals such as speeds, measurement impulses from the oil level sensor or clutch displacement
sensor and PWM signals should, if necessary, be checked with a Fluke ScopeMeter 123.
Multi-function measuring device – multimeter

Voltage and resistance values are determined using the multi-function measuring device (multimeter).
MAN item number: 08.78020-9021

DEVICE DESCRIPTION
Fluke ScopeMeter 123

Dynamic signals are monitored using the Fluke ScopeMeter 123.
MAN item number: 08.78023-0000
Troubleshooting program
The following troubleshooting program contains the faults that can be detected by the diagnostic memory.
The sequence of tests corresponds to the numerical succession of diagnostic codes (SPNs), irrespective of
the evaluation of the fault.
During initial vehicle testing, the entire diagnostic memory must always be read out and all the stored
faults documented. This is important because cables and/or components have to be disconnected during
troubleshooting and this means the corresponding fault messages may be set and saved. Consequently,
the diagnostic memory should always be deleted after intermediate inspections. If parts are replaced, send
a printout from MAN-cats verifying the fault together with the returned part in order to claim back the costs.
(The printout is an extract from the diagnostic memory, see above.)
Other procedures are only permitted subject to consultation with the Service Department in Munich!
Likewise, control units may only be exchanged under warranty subject to consultation with the Service
Department in Munich.
Repeat the check and delete the diagnostic memory after rectifying the fault and checking the repair work.
The diagnostic memory should always be deleted using MAN-cats
Always delete the diagnostic memory and observe the fault before replacing any components or
control units. If there are several diagnostic memory entries, always take test information into account
rst that does not require any components or control units to be replaced. Always switch off the
ignition before carrying out the repair and replacing components or control units. Failure to switch
off the ignition will lead to diagnostic memory entries (SPNs) in the various electronic control units.
Always carry out the "Check cables" step as follows:

– Disconnection or contact resistance (e.g. due to widened sockets, pushed back plugs/sockets or oxidised
plug connectors)
– Short-circuit to negative
– Short-circuit to positive
– Short-circuit to adjacent lines
– Loose contacts
– Water or moisture in the cable harness
Cable harnesses may be damaged even though the corrugated tube appears undamaged from the outside!
Break the connection to the control unit before measuring resistance values.
Refer to vehicle-specic circuit diagrams!
Resistance measurement
– Ignition “OFF”

DEVICE DESCRIPTION
– The break box is connected between the Power Train Manager and the vehicle.
– All jumpers must be closed in the break box. The jumper at which the value is being measured must be
open.
Voltage measurement
– Ignition “ON”
– All jumpers must be closed in the break box. Measurement for the "cruise control/gearbox" stalk switch is
also performed with the jumper open.
Voltage is measured with the engine running and the vehicle stationary.
SPN – diagnostic code description

This section presents the diagnostic codes that are shown on the combined instrument display or MAN-cats®
II screen in the event of a fault. The fault causes and responses are documented for the listed diagnostic
code descriptions.
SPN - Suspect Parameter Number – fault location
FMI - Failure Mode Identication - fault type
SPN SPN-Plain text

Description
00168 Battery voltage
Diagnosis status: FMI 1, too high
Priority: 3
Display at standstill, fault information only; no recommended action for the driver necessary.
Cause: Operating voltage is too high (> 32 V).
Rectication: Check the signal for plausibility with MAN-cats® II Monitoring, check the alternator,
check the lines, check the plug connectors, check the batteries.
Test steps:
Perform monitoring:
Check terminal 30 and terminal 15 signals for plausibility using MAN-cats® II (engine running,
rated value 20 to 28 V). If these values are OK, measure voltage.
Measure voltage:
Voltage measurement directly on the control unit pins VS/3 (terminal 15), VS/6 (terminal 30) and
VS/1 (-). Rated value 20 - 28 V. If the measured values (measured on the control unit connector)
are within the setpoint value range and the fault is still active, replace the Power Train Manager
(A1124).
00168 Battery voltage
Diagnosis status: FMI 2, too low
Priority: 3
Display at standstill, fault information only; no recommended action for the driver necessary.
Cause: Operating voltage is too low (< 16 V).
Rectication: Check the signal for plausibility with MAN-cats® II Monitoring, check the PTM
terminal 15 (F1027) and terminal 30 (F1026) fuses, check the lines, check the plug connectors,
check the steering wheel lock function (Q101), check the batteries, check the alternator.
Test steps:
Perform monitoring:
Check terminal 30 and terminal 15 signals for plausibility using MAN-cats® II (rated value 20 to
28 V). If these values are OK, measure voltage.
Measure voltage:
Voltage measurement directly on the control unit pins VS/3 (terminal 15), VS/6 (terminal 30) and
VS/1 (-) Rated value 20 - 28 V. If the measured values (measured on the control unit connector)
are within the setpoint value range and the fault is still active, replace the Power Train Manager
(A1124).

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05001 Accelerator travel percentage
Short description: This signal indicates the percentage accelerator travel between the end
position “not depressed” and the end position “fully depressed” from 0-100% when a fault occurs
for the rst time. There is no fault rectication because it is an ambient condition.
05002 Engaged gear
Short description: This signal shows the gear that was engaged when a fault occurs for the rst
time. There is no fault rectication because it is an ambient condition.
05003 Coolant temperature
Short description: This signal shows the coolant temperature when a fault occurs for the rst
05005 Engine speed (crankshaft)
Short description: This signal indicates the actual engine speed that is calculated using a
minimum crankshaft angle of 720 degrees divided by the number of cylinders, when a fault
occurs for the rst time. There is no fault rectication because it is an ambient condition.
05006 Rotational speed of input shaft
Short description: This signal shows the rotational speed of the input shaft when a fault occurs
05008 Rotational speed of output shaft
Short description: This signal shows the rotational speed of the output shaft when a fault occurs
05009 Voltage at terminal 15
Short description: This signal shows the voltage at terminal 15 when a fault occurs for the rst
05012 Voltage at terminal 30
Short description: This signal shows the voltage at terminal 30 when a fault occurs for the rst
05013 Vehicle speed TCO
Short description: This signal indicates the vehicle speed determined by the tachograph when
a fault occurs for the rst time. There is no fault rectication because it is an ambient condition.
05014 Time since ignition on
Short description: This signal shows the time the ignition is activated when a fault occurs for
the rst time. There is no fault rectication because it is an ambient condition.
05015 Vehicle speed at front axle
Short description: This signal shows the vehicle speed at the front axle when a fault occurs for
the rst time. There is no fault rectication because it is an ambient condition.
05500 Timeout CAN message EDC1
Short description: EDC1 is the name of the message from the EDC control unit (A435) and
contains signals regarding the EDC status, EDC operating mode, EDC mode, engine speed and
engine torque, amongst others.
Diagnosis status: FMI 4, no signal available
Priority: 2
Possibly workshop-relevant fault! Indicates malfunction

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
contains signals regarding the maximum-speed governor limiting torque and idling speed control,
amongst others.
Priority: 5
Display when vehicle in motion and at standstill; fault information only
contains signals regarding torque limiting and fuel supply pressure, amongst others.
Priority: 5
contains signals regarding the air lter and charging pressure, amongst others.
Priority: 5
contains signals regarding the engine coolant temperature, fuel temperature, air pressure and
exhaust gas temperature, amongst others.
Priority: 5
05505 Timeout engine conguration
Short description: The “engine conguration” message signal is sent from the EDC control unit
(A435).
Priority: 5
05507 Timeout ACC1
Short description: The message is sent from the ACC control unit (A479).
Priority: 5
05508 Timeout AIR1supplyPressure
Short description: The message is sent from the ECAM control unit (A409).
Priority: 5
05509 Timeout EBC1
Short description: EBC1 is the name of the message from the EBS control unit (A402) and
contains signals related to the brake pedal and/or the ABS and ASR statuses.
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05510 Timeout EBC2
supplies information on the wheel speed at the front axle/rear axle.
Priority: 5
05511 Timeout EBC3
supplies information on the brake pressure at the front axle/rear axle.
Priority: 4
No display
05513 Timeout engine uids
Short description: The “engine uids” message is sent from the EDC control unit (A435).
Priority: 5
05514 Timeout ERC1RD
Short description: The “ERC1RD” message is sent from the secondary retarder and contains
the maximum possible torque and current torque as a percentage value.
Priority: 5
05515 Timeout ERC1RE
Short description: The “ERC1RE” message is sent from the primary retarder and contains the
maximum possible torque and current torque as a percentage value.
Priority: 5
05518 Timeout high resolution vehicle distance
Short description: The “mileage” message is sent from the tachograph.
Priority: 4
No fault is indicated on the display, the central warning lamp does not light up or ash and no
other check lamp lights up.
05519 Timeout KSM1
Short description: The message is sent from the customer-specic module (A312).
Priority: 5
05520 Timeout KSM2
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05521 Timeout retarder conguration RD
Short description: The “secondary retarder conguration” message is sent from the secondary
retarder.
Priority: 5
05522 Timeout retarder conguration RE
Short description: The “primary retarder conguration” message is sent from the primary
retarder.
Priority: 5
05523 Timeout retarder uids RD
Short description: The “secondary retarder oil” message is sent from the secondary retarder.
Priority: 5
05524 Timeout retarder uids RE
Short description: The “primary retarder oil” message is sent from the primary retarder.
Priority: 5
05527 Timeout TCO1
Short description: The TCO1 message is sent from the tachograph (TCO) and contains the
driver identication and/or information on whether the vehicle is moving.
Priority: 5
05528 Timeout Time Date
Short description: The message is sent from the tachograph (TCO) and contains the time/date
data from the second to the year.
Priority: 4
No fault is indicated on the display, the central warning lamp does not light up or ash and no
other check lamp lights up.
05529 Timeout transmission uids
Short description: The “gearbox oil” message is sent from the manually operated gearbox or
automatic gearbox.
Priority: 5
05530 Timeout TSC1ABS2MC
Short description: The message is sent from the EBS control unit (A402).
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05531 Timeout TSC1ACC2ENG
Priority: 5
05532 Timeout TSC1ASR2ENG
Priority: 5
05533 Timeout TSC1TCU2ENG
Short description: The message is sent from the automatic gearbox.
Priority: 5
05534 Timeout TSC1TCU2RX
Short description: The message is sent from the manually operated gearbox or automatic
gearbox.
Priority: 5
05535 Timeout VDC1
Short description: VDC1 = Vehicle Dynamic Stability Control 1. The message is sent from the
ESP.
Priority: 5
05536 Timeout vehicle weight
Short description: The “vehicle weight” message is sent from the EBS control unit (A402).
Priority: 5
05537 Timeout XBR
Priority: 5
05538 Timeout ETC1
Short description: ETC1 = Electronic Transmission Control 1. The message is only sent if a
manually operated gearbox has been tted.
Priority: 5
05539 Timeout ETC2
Short description: ETC2 = Electronic Transmission Control 2. The number 2 denes the content
of the message and contains information about gear display and shift arrows.
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05540 Timeout DNR1
Short description: The LIN message is sent from the gearbox DNR switch (A434) if an automatic
gearbox has been tted.
Priority: 5
05541 Timeout LSS1
Short description: The LIN message is sent from the stalk switch for the retarder/gearbox
(A942).
Priority: 5
05542 Timeout LSS2
Short description: The LIN message is sent from the stalk switch for the cruise control/gearbox
(A429).
Priority: 5
05543 Timeout MFL1
Short description: The LIN message is sent from the multi-function steering wheel (A943).
Priority: 5
05544 DNR switch
Short description: The LIN message is sent from the gearbox DNR switch (A434).
Diagnosis status: FMI 8, signal faulty
Priority: 5
05544 DNR switch
Short description: The LIN message is sent from the gearbox DNR switch (A434).
Diagnosis status: FMI 9, device fault
Priority: 5
05545 Accelerator jams
Diagnosis status: FMI 3, implausible
Priority: 2
05546 Speed limitation with continuous brakes is not possible
Short description:
Priority: 5
05547 Speed limitation not possible
Short description:
Priority: 2

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05548 Engine start without start request
Short description: The signal is sent from the EDC control unit (A435).
Priority: 2
05549 Immobiliser pairing
Short description: The immobiliser (A477) is paired when setting the parameters between the
EDC control unit (A435) and the PTM control unit (A1124).
Priority: 5
05549 Immobiliser pairing
Short description: The immobiliser (A477) is paired when setting the parameters between the
EDC control unit (A435) and the PTM control unit (A1124).
Priority: 5
05550 Immobiliser transponder
Short description: The ignition key transponder signal is not known or cannot be read by the
electronic immobiliser (A477).
Priority: 5
05550 Immobiliser transponder
Short description: The ignition key transponder signal is not known or cannot be read by the
electronic immobiliser (A477).
Priority: 5
05551 CAN signal “Vehicle ABS active/passive”
Short description: The “vehicle ABS active/passive” message is sent from the EBS control unit
(A402).
Priority: 5
05551 CAN signal “Vehicle ABS active/passive”
Short description: The “vehicle ABS active/passive” message is sent from the EBS control unit
(A402).
Priority: 5
05552 actual engine torque
Short description: The “actual engine torque” message is sent from the EDC control unit (A435).
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05552 actual engine torque
Short description: The “actual engine torque” message is sent from the EDC control unit (A435).
Priority: 5
05553 CAN signal “Actual Retarder Percent Torque RD”
Short description: The “secondary retarder: current retarder torque in percent” message is sent
from the secondary retarder.
Priority: 5
05553 CAN signal “Actual Retarder Percent Torque RD”
Short description: The “secondary retarder: current retarder torque in percent” message is sent
from the secondary retarder.
Priority: 5
05554 CAN signal “Actual Retarder Percent Torque RE”
Short description: The “primary retarder: current retarder torque in percent” message is sent
from the primary retarder.
Priority: 5
05554 CAN signal “Actual Retarder Percent Torque RE”
Short description: The “primary retarder: current retarder torque in percent” message is sent
from the primary retarder.
Priority: 5
05555 Ambient temperature sensor ground
Short description: The signal is sent from the ambient air temperature sensor (B269).
Priority: 5
Diagnosis status: FMI 5, short-circuit to ground
Priority: 5
Diagnosis status: FMI 6, Short-circuit to UBat
Priority: 5
Diagnosis status: FMI 10, disconnection
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Diagnosis status: FMI 12, disconnection or short-circuit to UBat
Priority: 5
Diagnosis status: FMI 13, disconnection or short-circuit to ground
Priority: 5
05556 Ambient temperature sensor
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
05557 Fault, accelerator channel 1
Short description: The PWM1 signal is sent from the accelerator (A410).
Priority: 2

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Priority: 2
Priority: 2
Priority: 2
Priority: 2
Priority: 2
Priority: 2
Priority: 2
05559 CAN signal “Actual Maximum Available Retarder Percent Torque RD”
Short description: The message is sent from the secondary retarder.
Priority: 5
System reaction: It is not possible to monitor the secondary retarder with the Power Train
Manager.
05559 CAN signal “Actual Maximum Available Retarder Percent Torque RD”
Short description: The message is sent from the secondary retarder.
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05560 CAN signal “Barometric Pressure”
Short description: The message is sent from the EDC control unit (A435) and contains the air
pressure.
Priority: 5
05560 CAN signal “Barometric Pressure”
Short description: The message is sent from the EDC control unit (A435) and contains the air
pressure.
Priority: 5
05561 CAN signal “Engine Turbocharger Boost Pressure”
Short description: The “engine charging pressure” message is sent from the EDC control unit
(A435).
Priority: 5
05561 CAN signal “Engine Turbocharger Boost Pressure”
Short description: The “engine charging pressure” message is sent from the EDC control unit
(A435).
Priority: 5
05562 CAN signal “Brake Pedal Position”
Short description: The message is sent from the EBS control unit (A402). It contains information
about the position of the brake pedal.
Priority: 5
05562 CAN signal “Brake Pedal Position”
Short description: The message is sent from the EBS control unit (A402). It contains the
information about the position of the brake pedal.
Priority: 5
05570 Clutch displacement sensor
Short description: The signal is sent from the clutch displacement sensor (B362).
Priority: 2
Priority: 2

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Priority: 2
Priority: 2
05573 CAN signal “Disengage Driveline Request KSM”
Short description: The message is sent from the customer-specic module (A312). Declutch
request
Priority: 5
05573 CAN signal “Disengage Driveline Request KSM”
Priority: 5
05576 CAN signal “Engine Coolant Temperature”
Short description: The message is sent from the EDC control unit (A435). It contains the
information about the engine coolant temperature.
Priority: 5
05576 CAN signal “Engine Coolant Temperature”
information about the engine coolant temperature.
Priority: 5
05577 CAN signal “Engine Oil Pressure”
information about the engine oil pressure.
Priority: 5
05577 CAN signal “Engine Oil Pressure”
information about the engine oil pressure.
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05578 CAN signal “Engine Speed”
information about the engine speed.
Priority: 2
05578 CAN signal “Engine Speed”
information about the engine speed.
Priority: 2
05579 CAN signal “Request Engine Start KSM”
Short description: The message is sent from the customer-specic module (A312) and contains
an engine start request.
Priority: 5
05579 CAN signal “Request Engine Start KSM”
an engine start request.
Priority: 5
05580 CAN signal “Request Engine Stop KSM”
an engine stop request.
Priority: 5
05580 CAN signal “Request Engine Stop KSM”
an engine stop request.
Priority: 5
05581 Engine brake output
Short description: The output switches the engine brake solenoid valve (Y281).
Priority: 5
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Diagnosis status: FMI 7, short-circuit
Priority: 5
Priority: 5
Priority: 5
Priority: 5
05583 Main fan PWM output
Short description: The PWM output switches the fan clutch with speed sensor (A968).
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Priority: 5
05584 Fan speed sensor ground
Short description: The signal is sent from the fan clutch with speed sensor (A968).
Priority: 5
Priority: 5
Priority: 5
Priority: 5
05585 Power supply to fan speed sensor
Priority: 5
Priority: 5
Priority: 5
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Priority: 5
Priority: 5
Priority: 5
05586 Fan speed frequency input
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Priority: 5
Priority: 5
05587 CAN signal “Front axle, Left Wheel Speed”
Short description: The “front axle, left wheel speed” message is sent from the EBS control unit
(A402).
Priority: 4
No display
05587 CAN signal “Front axle, Left Wheel Speed”
Short description: The “front axle, left wheel speed” message is sent from the EBS control unit
(A402).
Priority: 4
No display
05588 CAN signal “Front axle, Right Wheel Speed”
Short description: The “front axle, right wheel speed” message is sent from the EBS control
unit (A402).
Priority: 4
No display
05588 CAN signal “Front axle, Right Wheel Speed”
Short description: The “front axle, right wheel speed” message is sent from the EBS control
unit (A402).
Priority: 4
No display
05589 CAN signal “Front Axle Speed”
Short description: The “front axle speed” message is sent from the EBS control unit (A402).
Priority: 4
No display
05589 CAN signal “Front Axle Speed”
Short description: The “front axle speed” message is sent from the EBS control unit (A402).
Priority: 4
No display
05590 CAN signal “Engine Fuel Delivery Pressure”
Short description: The “engine fuel delivery pressure” message is sent from the EDC control
unit (A435).
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05590 CAN signal “Engine Fuel Delivery Pressure”
Short description: The “engine fuel delivery pressure” message is sent from the EDC control
unit (A435).
Priority: 5
05591 Gearbox input speed sensor ground
Short description: The signal is sent from the gearbox input speed inductive pickup (B368).
Priority: 5
05591 Gearbox input speed sensor ground
Priority: 5
05592 Frequency input, gearbox input speed sensor
Priority: 5
Priority: 5
Priority: 5
05593 CAN signal “Immobiliser EDC”
Short description: The “immobiliser EDC” message is sent from the EDC control unit (A435).
Priority: 5
05593 CAN signal “Immobiliser EDC”
Short description: The “immobiliser EDC” message is sent from the EDC control unit (A435).
Priority: 5
05595 CAN signal “Input Shaft Speed”
Short description: The “input shaft speed” message is sent from the manually operated gearbox
or automatic gearbox.
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05595 CAN signal “Input Shaft Speed”
Short description: The “input shaft speed” message is sent from the manually operated gearbox
Priority: 5
05596 CAN signal “Engine Intake Manifold 1 Temperature”
Short description: The “engine intake manifold 1 temperature” message is sent from the EDC
control unit (A435).
Priority: 5
05596 CAN signal “Engine Intake Manifold 1 Temperature”
Short description: The “engine intake manifold 1 temperature” message is sent from the EDC
Priority: 5
05597 CAN signal “EDCmode”
Short description: The “EDCmode” message is sent from the EDC control unit (A435).
Priority: 5
05597 CAN signal “EDCmode”
Short description: The “EDCmode” message is sent from the EDC control unit (A435). The
start status of the engine control system is transferred.
Priority: 5
05598 CAN signal “Gearbox mode”
Short description: The “gearbox mode” message is sent from the manually operated gearbox
Priority: 5
05598 CAN signal “Gearbox mode”
Short description: The “gearbox mode” message is sent from the manually operated gearbox
Priority: 5
05599 CAN signal “Momentary Engine Overspeed Enable”
Short description: The “momentary engine overspeed enable” message is sent from the EDC
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05599 CAN signal “Momentary Engine Overspeed Enable”
Short description: The “momentary engine overspeed enable” message is sent from the EDC
Priority: 5
05600 CAN signal “Nominal Friction-Percent Torque”
Short description: The “nominal friction-percent torque” message is sent from the EDC control
unit (A435).
Priority: 5
05600 CAN signal “Nominal Friction-Percent Torque”
Short description: The “nominal friction-percent torque” message is sent from the EDC control
unit (A435).
Priority: 5
05608 Oil level sensor
Short description: The signal is sent from the oil level sensor (B270)
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
05609 Oil level sensor ground
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Priority: 5
Priority: 5
Priority: 5
05610 Oil temperature sensor
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Priority: 5
Priority: 5
05611 CAN signal “Tachograph Output Shaft Speed”
Short description: The “tachograph output shaft speed” message is sent from the manually
operated gearbox or automatic gearbox.
Priority: 5
05611 CAN signal “Tachograph Output Shaft Speed”
Short description: The “tachograph output shaft speed” message is sent from the manually
Priority: 5
05612 CAN signal “Transmission Output Shaft Speed”
Short description: The “transmission output shaft speed” message is sent from the manually
Priority: 5
05612 CAN signal “Transmission Output Shaft Speed”
Short description: The “transmission output shaft speed” message is sent from the manually
Priority: 5
05614 CAN signal “Engine Percent Load at Current Speed”
Short description: The “engine percent load at current speed” message is sent from the EDC
Priority: 5
05614 CAN signal “Engine Percent Load at Current Speed”
Short description: The “engine percent load at current speed” message is sent from the EDC
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05615 Ground, exhaust gas back pressure sensor
Short description: The signal is sent from the EVB module (Y355)
Priority: 5
Priority: 5
Priority: 5
Priority: 5
05616 Power supply, exhaust gas back pressure sensor
Priority: 5
Short description: The message is sent from the EVB module (Y355).
Priority: 5
Priority: 5
Priority: 5
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Priority: 5
05617 Exhaust gas back pressure sensor
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05618 CAN signal “Brake Application Pressure High Range, Front Axle, Left Wheel”
Short description: The “brake application pressure high range, front axle, left wheel” message
is sent from the EBS control unit (A402).
Priority: 4
No display
05618 CAN signal “Brake Application Pressure High Range, Front Axle, Left Wheel”
Short description: The “brake application pressure high range, front axle, left wheel” message
Priority: 4
No display
05619 CAN signal “Brake Application Pressure High Range, Front Axle, Right Wheel”
Short description: The “brake application pressure high range, front axle, right wheel” is sent
from the EBS control unit (A402).
Priority: 4
No display
05619 CAN signal “Brake Application Pressure High Range, Front Axle, Right Wheel”
Short description: The “brake application pressure high range, front axle, right wheel” is sent
from the EBS control unit (A402).
Priority: 4
No display
05620 CAN signal “Brake Application Pressure High Range, Rear Axle #1, Left Wheel”
Short description: The “brake application pressure high range, rear axle #1, left wheel” message
Priority: 4
No display
05620 CAN signal “Brake Application Pressure High Range, Rear Axle #1, Left Wheel”
Short description: The “brake application pressure high range, rear axle #1, left wheel” message
Priority: 4
No display
05621 CAN signal “Brake Application Pressure High Range, Rear Axle #1, Right Wheel”
Short description: The “brake application pressure high range, rear axle #1, right wheel”
message is sent from the EBS control unit (A402).
Priority: 4
No display
05621 CAN signal “Brake Application Pressure High Range, Rear Axle #1, Right Wheel”
Short description: The “brake application pressure high range, rear axle #1, right wheel”
message is sent from the EBS control unit (A402).
Priority: 4
No display

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05622 PTO1 high side output
Short description: The output switches power take-off 1.
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Priority: 5
Priority: 5
Priority: 5
05626 Range-change group switch input
Short description: The signal is sent from the manually operated gearbox or automatic gearbox.
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
05627 CAN signal “Engine Reference Engine Torque (Engine Conguration)”
Short description: The “reference engine torque (engine conguration)” message is sent from
the EDC control unit (A435).
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05627 CAN signal “Engine Reference Engine Torque (Engine Conguration)”
Short description: The “reference engine torque (engine conguration)” message is sent from
the EDC control unit (A435).
Priority: 5
05628 CAN signal “Reference Retarder Torque RD”
Short description: The “reference retarder torque secondary retarder” message is sent from the
secondary retarder.
Priority: 5
05628 CAN signal “Reference Retarder Torque RD”
Short description: The “reference retarder torque secondary retarder” message is sent from the
secondary retarder.
Priority: 5
05629 CAN signal “Reference Retarder Torque RE”
Short description: The “reference retarder torque primary retarder” message is sent from the
primary retarder.
Priority: 5
05629 CAN signal “Reference Retarder Torque RE”
Short description: The “reference retarder torque primary retarder” message is sent from the
primary retarder.
Priority: 5
05630 CAN signal “Engine Requested Speed/Speed Limit EBS2ENG”
Priority: 5
05630 CAN signal “Engine Requested Speed/Speed Limit EBS2ENG”
Priority: 5
05631 CAN signal “Engine Requested Speed/Speed Limit TCU2ENG”
gearbox.
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05631 CAN signal “Engine Requested Speed/Speed Limit TCU2ENG”
gearbox.
Priority: 5
05632 CAN signal “Engine Requested Torque/Torque Limit EBS2ENG”
Priority: 5
05632 CAN signal “Engine Requested Torque/Torque Limit EBS2ENG”
Priority: 5
05633 CAN signal “Engine Requested Torque/Torque Limit EBS2MC”
Priority: 5
05633 CAN signal “Engine Requested Torque/Torque Limit EBS2MC”
Priority: 5
05634 CAN signal “Engine Requested Torque/Torque Limit TCU2ENG”
gearbox.
Priority: 5
05634 CAN signal “Engine Requested Torque/Torque Limit TCU2ENG”
gearbox.
Priority: 5
05635 CAN signal “Engine Requested Torque/Torque Limit TCU2TX”
gearbox.
Priority: 5
05635 CAN signal “Engine Requested Torque/Torque Limit TCU2TX”
gearbox.
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05636 CAN signal “Engine Requested Speed Control Conditions EBS2ENG”
Priority: 5
05637 CAN signal “Engine Requested Speed Control Conditions TCU2ENG”
gearbox.
Priority: 5
05638 CAN signal “Transmission Gear Shift Inhibit Request KSM”
gearbox.
Priority: 5
05638 CAN signal “Transmission Gear Shift Inhibit Request KSM”
gearbox.
Priority: 5
05640 CAN signal “Acknowledge Start Command”
Short description: The message is sent from the EDC control unit (A435).
Priority: 5
05640 CAN signal “Acknowledge Start Command”
Priority: 5
05641 CAN signal “EGR Status”
Priority: 5
05641 CAN signal “EGR Status”
Priority: 5
05642 CAN signal “Automatic Status”
gearbox.
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05642 CAN signal “Automatic Status”
gearbox.
Priority: 5
05643 CAN signal “Emergency Start Request”
Priority: 5
05643 CAN signal “Emergency Start Request”
Priority: 5
05644 CAN signal “Zero Quantity Request Due To Engine Brake”
Priority: 5
05644 CAN signal “Zero Quantity Request Due To Engine Brake”
Priority: 5
05645 CAN signal “Start Request”
Priority: 5
05645 CAN signal “Start Request”
Priority: 5
05646 CAN signal “Zero Quantity Request Due To Engine Stop”
Priority: 5
05646 CAN signal “Zero Quantity Request Due To Engine Stop”
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05647 Voltage, term. 15
Short description: The power supply to terminal 15 is protected by the PTM terminal 15 fuse
(F1026).
Priority: 5
05648 Voltage, term. 30
Short description: The power supply to terminal 30 is protected by the PTM terminal 30 fuse
(F1027).
Priority: 5
05650 CAN signal “Torque Converter Lockup Disable Request KSM”
Priority: 5
05650 CAN signal “Torque Converter Lockup Disable Request KSM”
Priority: 5
05651 CAN signal “EDR Limiting Torque”
Priority: 5
05651 CAN signal “EDR Limiting Torque”
Priority: 5
05652 CAN signal “MBEG Limiting Torque”
Priority: 5
05652 CAN signal “MBEG Limiting Torque”
Priority: 5
05653 CAN signal “LLR Torque”
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05653 CAN signal “LLR Torque”
Priority: 5
05654 CAN signal “Transmission Actual Gear Ratio”
gearbox.
Priority: 5
05654 CAN signal “Transmission Actual Gear Ratio”
gearbox.
Priority: 5
05658 CAN signal “Highest Possible Gear”
gearbox.
Priority: 3
Display at standstill, fault information only; no recommended action necessary
05658 CAN signal “Highest Possible Gear”
gearbox.
Priority: 3
05660 CAN signal “Lowest Possible Gear”
gearbox.
Priority: 3
05660 CAN signal “Lowest Possible Gear”
gearbox.
Priority: 3
05663 CAN signal “Recommended Gear”
gearbox.
Priority: 3

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05663 CAN signal “Recommended Gear”
gearbox.
Priority: 3
05664 CAN signal “Transmission Selected Gear”
gearbox.
Priority: 3
05664 CAN signal “Transmission Selected Gear”
gearbox.
Priority: 3
05668 CAN signal “Tachograph Vehicle Speed”
Short description: The message is sent from the tachograph.
Priority: 3
05668 CAN signal “Tachograph Vehicle Speed”
Short description: The message is sent from the tachograph.
Priority: 3
05671 CAN signal “Gross Combination Vehicle Weight MC”
Short description: The message is sent from the control unit?
Priority: 5
05671 CAN signal “Gross Combination Vehicle Weight MC”
Short description: The message is sent from the control unit?
Priority: 5
05672 Switch to shift gearbox into neutral
Short description: The message is sent from the neutral position switch (S172).
Priority: 5
05672 Switch to shift gearbox into neutral
Short description: The message is sent from the neutral position switch (S172).
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05674 The “Current Gear” signal cannot be calculated.
Short description: The signal cannot be calculated for a manually operated gearbox.
Priority: 5
05675 The “Transmission Requested Gear” signal cannot be calculated.
Short description: The signal cannot be calculated for an automatic gearbox.
Priority: 5
05675 The “Transmission Requested Gear” signal cannot be calculated.
Priority: 5
05676 The “Transmission Requested Range Direction” signal cannot be calculated.
Priority: 5
05676 The “Transmission Requested Range Direction” signal cannot be calculated.
Priority: 5
05677 The “Requested Range” signal cannot be calculated.
Priority: 5
05677 The “Requested Range” signal cannot be calculated.
Priority: 5
05680 The “Transmission Actual Gear Ratio” signal cannot be calculated.
Short description: The signal cannot be calculated for a manually operated gearbox.
Priority: 5
05681 Diagnosis CAN bus off
Short description: In the event of Bus-Off, the control unit is not taking part in CAN
communication. The signal is sent from the diagnosis CAN data bus.
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05682 Engine CAN bus off
communication. The signal is sent from the engine CAN data bus.
Priority: 2
05683 Driveline CAN bus off
communication. The signal is sent from the driveline CAN data bus.
Priority: 2
05684 Comfort Shift
Short description: The signal is sent from the gear selector lever switch (S477).
Priority: 5
05684 Comfort Shift
Short description: The signal is sent from the gear selector lever switch (S477).
Priority: 5
05685 Accelerator signal
Short description: The signal is sent from the accelerator unit (A410).
Priority: 2
Priority: 2
Priority: 2
05686 Main fan speed
Short description: The message is sent from the fan clutch with speed sensor (A968).
Priority: 2
05687 Clutch servo output, high side
Short description: The output switches the clutch servo (Y308).
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
05688 Clutch servo output, low side
Priority: 5
Priority: 5
Priority: 5
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Priority: 5
05689 Gate lock output, high side
Short description: The output switches the solenoid valve for the splitter box and range-change
group (Y307).
Priority: 5
group (Y307).
Priority: 5
group (Y307).
Priority: 5
group (Y307).
Priority: 5
05690 Range-change group output, high side
group (Y307).
Priority: 5
group (Y307).
Priority: 5
group (Y307).
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
group (Y307).
Priority: 5
05691 Low range output, high side
group (Y307).
Priority: 5
group (Y307).
Priority: 5
group (Y307).
Priority: 5
group (Y307).
Priority: 5
05692 Range actuation output, low side
group (Y307).
Priority: 5
group (Y307).
Priority: 5
group (Y307).
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05693 Split High output, high side
group (Y307).
Priority: 5
group (Y307).
Priority: 5
group (Y307).
Priority: 5
05694 Split Low output, high side
group (Y307).
Priority: 5
group (Y307).
Priority: 5
group (Y307).
Priority: 5
05696 Split output, low side
group (Y307).
Priority: 5
group (Y307).
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
group (Y307).
Priority: 5
05698 CAN signal "PTO1 Permission"
Short description: The message is sent from power take-off 1.
Priority: 5
Priority: 5
Priority: 5
Priority: 5
05702 Transmission gearshift/gear change
Short description: The signal is sent from the gearbox control unit.
Priority: 5
05702 Transmission gearshift/gear change
Priority: 5
05704 Current, purely speed-related, virtual gearbox transmission ratio
Short description: The message is sent from the gearbox control unit.
Priority: 5
05704 Current, purely speed-related, virtual gearbox transmission ratio
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
05708 Service due
Diagnosis status: FMI 0, fault not specied
Priority: 3
05709 Service due
Priority: 5
05711 Service due
Short description:
Priority: 5
5712 Oil level
Short description: Signal
Priority: 5
5712 Oil level
Short description: Signal
Priority: 5
05713 LIN bus, DNR switch
Short description: The message is sent from the gearbox DNR switch (A434).
Priority: 5
05714 LIN bus, multi-function steering wheel/stalk switch
Short description: In vehicles tted with a multi-function steering wheel, the message is
sent from the combined instrument (A407), stalk switch for the retarder/gearbox (A942) and
multi-function steering wheel (A943). In vehicles not tted with a multi-function steering
wheel, the message is sent from the combined instrument (A407), stalk switch for the cruise
control/gearbox (A942) and continuous brakes tip switch (A943).
Priority: 5
05715 Internal fault
Short description: The message is sent from the Power Train Manager (A1124) - application
timeout.
Priority: 1
In conjunction with STOP symbol. Engine must be stopped!

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Short description: The message is sent from the Power Train Manager (A1124). The power
supply cannot be switched off due to a hardware problem.
Priority: 2
Short description: The message is sent from the Power Train Manager (A1124). Cycled digital
inputs cannot be read due to a hardware problem.
Priority: 1
Short description: The message is sent from the Power Train Manager (A1124) - checksum
fault in the code (program and data).
Priority: 1
Short description: The message is sent from the Power Train Manager (A1124). There is an
internal program fault in the basic software.
Priority: 1
Short description: The message is sent from the Power Train Manager (A1124). There is an
internal program fault in one of the applications.
Priority: 1
Short description: The message is sent from the Power Train Manager (A1124). There is a
hardware fault (in the Power Train Manager) when measuring the oil level.
Priority: 1
Short description: The message is sent from the Power Train Manager (A1124). The reference
voltage for the analogue inputs is invalid. The analogue signals thus become invalid.
Priority: 2
Short description: Hardware fault in the Power Train Manager; internal program fault (stack
overow)
Priority: 1

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Short description: Software error in the Power Train Manager; computing timeout in the system
phase (basic software)
Diagnosis status: FMI 1 Too high
Priority: 1
Short description: Hardware fault in the Power Train Manager; watchdog has been triggered
Priority: 1
Short description: Application 1 PTM standard in the Power Train Manager is invalid.
Priority: 1
Short description: Application 2 PTM safety in the Power Train Manager is invalid.
Priority: 1
Short description: Application 3 PTM external in the Power Train Manager is invalid.
Priority: 1
Short description: Middleware version is invalid.
Priority: 2
Short description: Unable to save EEPROM data in full as the last shutdown was interrupted
(terminal 15 and terminal 30 off). Fault will be saved at the next ignition activation cycle and reset
at the cycle thereafter.
Priority: 4
No display
Short description: ROM replacement values are used for parameters due to EEPROM fault.
Priority: 1
Short description: ROM replacement values are used for operating data due to EEPROM fault.
Priority: 1

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Short description: There are invalid parameters. Backup values will be used if they are valid.
Priority: 1
Short description: There is invalid operating data. Backup values will be used if they are valid.
Priority: 4
No display
Short description: Loaded basic software does not match Power Train Manager hardware.
Priority: 1
Short description: There is an internal software error in the operating system of the basic
software.
Priority: 1
Short description: Hardware fault (in the Power Train Manager); RAM test failed
Priority: 1
Short description: Hardware fault (in the Power Train Manager); watchdog is faulty
Priority: 1
Short description: Outputs are switched off due to overload at the high-side drivers. Is the
original fault for overload at the high-side outputs. Occurs if several outputs are under high load
but do not yet switch off of their own accord (through detection of a short-circuit).
Priority: 1
5747 Worn clutch
Short description: Clutch slip occurs frequently over relatively long period of time. Clutch may
be worn.
Priority: 4
No display
5748 Timeout ACC2prop
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
5748 Timeout ACC2prop
Priority: 5
5749 CAN signal "externalAccelerationDemand" faulty
Priority: 5
5749 CAN signal "externalAccelerationDemand" faulty
Priority: 5
5750 CAN signal "coastReq"
Priority: 5
5750 CAN signal "coastReq"
Priority: 5
5751 CAN signal "overrideControlModePriority"
Priority: 5
5751 CAN signal "overrideControlModePriority"
Priority: 5
5752 CAN signal "VHTS_TscOcmVeh01"
Priority: 5
5752 CAN signal "VHTS_TscOcmVeh01"
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
5753 CAN signal "freezeEBreq"
Priority: 5
5753 CAN signal "freezeEBreq"
Priority: 5
5754 CAN signal "ACCmode"
Priority: 5
5754 CAN signal "ACCmode"
Priority: 5
Short description: Exhaust gas back pressure sensor (EVBec) not plausible
Priority: 5
5757 Exhaust gas back pressure sensor or proportional control, EVBec
Short description: Fault at proportional valve and/or exhaust gas back pressure sensor of the
EVBec
Priority: 5
5758 EVB proportional valve or exhaust throttle valve
Short description: Fault due to proportional valve or exhaust gas blockage
Priority: 5
5759 Calibration status of the clutch pedal travel
Short description: Fault is output if the clutch is not calibrated.
Priority: 4
No display
5764 Signal, terminal 50
Short description: If terminal 50 is activated for longer than parametrised, the system detects
a fault
Diagnosis status: FMI 3
Priority: 2

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
5765 Immobiliser tampering
Short description:
Priority: 4
No display
5766 Engine CAN break
Short description:
Priority: 2
5767 Engine stop request plausibility check
Short description:
Priority: 5
5768 Absolute clutch travel
Short description: In the case of manually operated gearboxes, the fault is sent from the PTM.
Priority: 5
5769 Failure of cruise control operation
Priority: 5
5771 Internal fault
Short description: EEROM2 replacement values are used for parameters due to EEPROM2
fault.
Priority: 1
5772 Internal fault
Short description: Invalid EEPROM2 parameters
Priority: 1
5773 Maximum speed limitation input - PINs
Priority: 5
Priority: 5
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
Priority: 5
Priority: 5
Priority: 5
5774 Torque speed limitation input - PINs
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
Priority: 5
5783 Timeout CAN message, consumption l/h
Short description:
Priority: 5
5784 ACC CAN bus off
Short description:
Priority: 2

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
5797 Timeout ACCrefInfo
Short description:
Priority: 4
No display
5798 Timeout ACCvehicle2
Short description:
Priority: 4
No display
5799 Timeout AEBS1
Short description:
Priority: 4
No display
5800 Timeout AEBSvehicle1
Short description:
Priority: 4
No display
5801 Timeout XBR from ACC sensor at CAN4
Short description:
Priority: 5
5802 Timeout DPFcontrol1
Short description:
Priority: 4
No display
5803 Timeout EDC6
Short description:
Priority: 5
5804 Timeout EDC7
Short description:
Priority: 5
5805 Timeout engine uids
Short description:
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
5806 Timeout engine temperature
Short description:
Priority: 5
5807 Timeout ERC1RX
Short description:
Priority: 5
5808 Timeout retarder conguration RX
Short description:
Priority: 5
5809 Timeout auxStatZBR1
Short description: Message from the central on-board computer for the switch states and check
lamps
Priority: 4
No display
5810 Timeout EBC5
Short description:
Priority: 4
No display
5811 Timeout TSC1ATC2ENG
Short description:
Priority: 5
5812 Timeout TSC1BVI2ENG
Short description:
Priority: 5
5813 Timeout VDC2
Short description:
Priority: 5
5814 Timeout TCI
Short description:
Priority: 5

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
6000 Gearbox control fault
Short description: Is a collective SPN and denes the fault text on the display. Nothing is
displayed in MAN-cats® II.
Priority: none
Cause: Fault occurred for which a collective SPN is stored.
Rectication: no fault rectication possible
6001 Oil level monitoring fault
Priority: none
6002 Check engine oil level
Priority: none
6003 Electrical system fault
Priority: none
6004 Continuous brake fault
Priority: none
6005 Cruise control fault
Priority: none
6006 Brake control fault
Priority: none

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
6007 Engine control fault
Priority: none
6008 ACC fault
Priority: none
6009 ESP fault
Priority: none
6011 PTO fault
Priority: none
6012 Clutch lining wear
Priority: none
6013 Actuate clutch
Priority: none
6014 Clutch overload, downshift
Priority: none

DEVICE DESCRIPTION
SPN SPN-Plain text

Description
6015 SHIFT TO NEUTRAL
Priority: none
6016 Service due
Priority: none
6017 Engine cooling fault
Priority: none
6018 Clutch
Priority: none
6039 Timeout ACCvehicle1
Short description:
Priority: 4
No display

DEVICE DESCRIPTION
Test step list

The test step list allows you to check the components and/or functions of the Power Train Manager using the
break box, a multi-function measuring device (multimeter) and a Fluke ScopeMeter 123.
Test description
In the test step list indicated in this section (example: test step 1), the rst test contact is designated as “pin
C/19”. The second test contact is designated as “pin VS/1”.
A cover plate is placed onto the break box. This cover plate indicates the Power Train Manager plug
connectors.
The measuring mode to be set on the multi-function measuring device (multimeter) is shown between the
test contacts listed in column 2.
Example: Setting "V" = Voltage measurement
Example: Setting "Ω" = Resistance measurement
Once the test conditions have been met, the value displayed on the multi-function measuring device
(multimeter) (actual property) can be compared with the setpoint value (nominal property).
The break box is connected between the Power Train Manager and the vehicle. All jumpers must be closed
in the break box. The jumper at which the value is being measured must be open.
Test step list for Power Train Manager (A1124)
Service outlet: Test performed by:

Customer: First registration:
Vehicle type: Vehicle identier:
Engine type: Engine number:
CR high pressure pump: Control unit no.:
Mileage: Date:
Read out the diagnostic memory of the Power Train Manager using MAN-cats® II. Use the test step
list to locate the entered active faults.
– Use brief overviews and/or circuit diagrams for the specic vehicle in question when troubleshooting.
– Voltage measurements are taken with the ignition switched on, the engine running and the vehicle stationary.
– Resistance measurements are taken with the ignition switched off.
– Voltage and resistance values are measured between the positive connection (pin+) and negative
connection (pin-) on the multi-function measuring device (multimeter).
– Never measure at the plug contacts themselves without using suitable test probes! Danger of
bending open the contacts!
Resistance measurement
– Ignition OFF
– All jumpers must be closed in the break box. The jumper at which the value is being measured must be
open.
Comment: Pin VS/1 is connected to terminal 31 - battery ground.

DEVICE DESCRIPTION
Digital inputs
For this purpose, the vehicle side must be completely disconnected on the terminal tester in order to prevent
incorrect measurements!
Measuring device Setpoint Measured

PTM pin designation
Pin+ Pin- value [Ω] value [Ω]
External engine stop request

C/19 VS/1
Reverse-gear interlock ~= 62 kΩ ..................
Cable number 43315 31000
External engine start request
Parking brake relay for start/stop C/7 VS/1
(K266) ~= 62 kΩ ..................

Ignition switch request for engine start,
terminal 50
Steering wheel lock (Q101), plug
C/17 VS/1
conn. Starter interlock (X669), starter ~= 62 kΩ ..................
interlock relay for refrigerated body
(K871)
Intelligent brake request (linking)
C/34 VS/1
Continuous brake button (S1133) ~= 22 kΩ ..................
Cruise control/road speed limiter
request
C/46 VS/1
switch (S284) ~= 22 kΩ ..................
Closed: Road speed limiter
Open: Cruise control
Power take-off 1 request
C/31 VS/1
Power take-off 1 switch (S222) ~= 22 kΩ ..................
C/43 VS/1
Power take-off 2 switch (S223) ~= 22 kΩ ..................
Splitter switch request
Gear selector lever switch (S477)
C/21 VS/1
Closed: Split Low ~= 22 kΩ ..................
Open: Split High
Comfort Shift 1 request
C/12 VS/1
Gear selector lever switch (S477) ~= 13.7 kΩ ..................
Comfort Shift 2 request (redundant
input) C/33 VS/1
Gear selector lever switch (S477) ~= 15.7 kΩ ..................

DEVICE DESCRIPTION

PTM pin designation
Pin+ Pin- value [Ω] value [Ω]
Intermediate speed control 1 request

C/23 VS/1
ZDR interface (X1996 pin 2) ~= 22 kΩ ..................
C/35 VS/1
C/47 VS/1
Gearbox neutral position feedback
C/48 VS/1
Neutral position switch (S172) ~= 24 kΩ ..................
Power take-off 1 feedback
Power take-off display switch (S219), C/44 VS/1
power take-off switch (S222) ~= 24 kΩ ..................

Power take-off 2 display switch C/8 VS/1
(S220), power take-off 2 switch (S223) ~= 24 kΩ ..................

Engine brake request
Pl. con. for multi-function steering
C/10 VS/1
wheel (X4397 pin 5), continuous brake ~= 24 kΩ ..................
tip switch (A437)
Parking brake feedback
C/20 VS/1
Parking brake check switch (B369) ~= 24 kΩ ..................
Frequency inputs
Setpoint Measured
Measuring device
PTM pin designation value [Ω] value [Ω]
Pin+ Pin- PTM PTM
Gearbox speed sensor
Inductive pickup, gearbox input speed B/8 VS/1
(B368) ~= 1.85 kΩ .........

Main fan speed
Sensor B/43 VS/1
Fan clutch with speed sensor (A968) ~= 250 kΩ .........

Immobiliser data line
Immobiliser electronics (A477)
B/31 VS/1
not present ~= 3 kΩ .........
present

DEVICE DESCRIPTION
Analogue inputs
Setpoint Measured
Measuring device
Pin+ Pin- PTM PTM
Maximum speed limitation request
ZDR interface (X1996), EDC resistor C/26 VS/1
group (R134) ~= 11 kΩ .........

Engine torque limitation request
ZDR interface (X1996), EDC resistor C/37 VS/1
group (R134) ~= 34 kΩ .........

Oil temperature sensor - engine oil
temperature B/33 VS/1
Oil level sensor (B270) ~= 31 kΩ .........

Range-change group change request
C/14 VS/1
Gear selector lever switch (S477) ~= 5 kΩ .........
Clutch displacement sensor signal
detection B/34 VS/1
Clutch displacement sensor (B362) ~= 6.8 kΩ .........

Exhaust gas back pressure signal
B/21 VS/1
EVB module (Y355) ~= 20 kΩ .........
Cable number/colour blue 31000
Analogue outputs
Setpoint Measured
Measuring device
Pin+ Pin- PTM PTM
5 V supply to exhaust gas back
pressure sensor/brake pedal sensor B/13 VS/1
EVB module (Y355) ~= 155 kΩ .........

5 V supply for main fan speed
B/25 VS/1
CAN data bus
Setpoint Measured
Measuring device
Pin+ Pin- PTM PTM
Resistance betw. driveline CAN High
B/6 B/18
and driveline CAN Low ~= 120 Ω .........
Cable colour Blue/red Blue/white

DEVICE DESCRIPTION
Setpoint Measured
Measuring device
Pin+ Pin- PTM PTM
Resistance betw. engine CAN High
B/5 B/17
and engine CAN Low ~= 120 Ω .........
PWM outputs
Setpoint Measured
Measuring device
Pin+ Pin- PTM PTM
Engine brake
Solenoid valve for engine brake B/37 VS/1
(Y281) ~= 143 kΩ .........

Fan clutch
B/38 VS/1
Solenoid valve for range-change
group, low
A/27 VS/1
Solenoid valve for splitter box and ~= 143 kΩ .........
range-change group (Y307)
group, high
A/39 VS/1
Solenoid valve for High split position
Solenoid valve for splitter box and A/14 VS/1
range-change group (Y307) ~= 143 kΩ .........

Solenoid valve for Low split position

Clutch servo
A/3 VS/1
Clutch servo (Y308) ~= 143 kΩ .........

DEVICE DESCRIPTION
Digital outputs
Setpoint Measured
Measuring device
Pin+ Pin- PTM PTM
Power take-off 1
Solenoid valve for power take-off 1 A/20 VS/1
(Y153) ~= 143 kΩ .........

Power take-off 2
Solenoid valve for power take-off 2 A/21 VS/1
(Y154) ~= 143 kΩ .........

Solenoid valve for gate lock

Ground shut-off, solenoid valve for
range-change group
A/28 VS/1
Ground clutch servo
A/17 VS/1
Clutch servo (Y308) ~= 168 kΩ .........
Assemblies, sensors
Setpoint Measured
Measuring device
Pin+ Pin- PTM PTM
temperature B/33 B/47
Oil level sensor (B270) ~= 1.9 kΩ .........

Power take-off 1
Solenoid valve for power take-off 1
(Y153) A/20 A/9 ~= 40 Ω .........
Fitted Innite .........
Not tted
Cable number 40329
Power take-off 2
Solenoid valve for power take-off 2
(Y154) A/21 A/8 ~= 40 Ω .........
Fitted Innite .........
Not tted
Cable number 40330
group, high
A/39 A/28
Solenoid valve for splitter box and ~= 131 Ω .........

DEVICE DESCRIPTION
Setpoint Measured
Measuring device
Pin+ Pin- PTM PTM
group, low
A/27 A/28
Solenoid valve for splitter box and ~= 131 Ω .........
Solenoid valve for splitter box and A/26 A/28
range-change group (Y307) ~= 131 Ω .........

Solenoid valve for High split position

Solenoid valve for Low split position

Clutch servo
A/3 A/17
Clutch servo (Y308) ~= 47 Ω .........
Clutch displacement sensor signal
detection B/34 B/22
Clutch displacement sensor (B362) ~= 72 Ω .........

Inductive pickup, gearbox input speed B/8 B/35
(B368) ~= 1 kΩ .........
Ground
Setpoint Measured
Measuring device
Pin+ Pin- PTM PTM
Ground of resistor group for engine
torque limitation/maximum speed
B/36 VS/1
limitation Innite .........
EDC resistor group (R134)
Ground, temperature sensor, outside
air
B/11 VS/1
Temperature sensor, outside air Innite .........
(B269)
Ground of oil level sensor - engine oil
level/engine oil temperature B/47 VS/1
Oil level sensor (B270) ~= 4.3 MΩ .........

DEVICE DESCRIPTION
Setpoint Measured
Measuring device
Pin+ Pin- PTM PTM
Ground, clutch displacement sensor
B/22 VS/1
Clutch displacement sensor (B362) ~= 175 kΩ .........
Ground of gearbox speed sensor
inductive pickup B/35 VS/1
Gearbox input speed (B368) Innite .........
Torque speed limitation
R min R max Measured

Measuring device
Torque speed limitation [Ω] [Ω] value [Ω]
Pin+ Pin- R134 R134 R134
Stage 1 8 5
411 612 .........
Stage 2 3 5
1103 1651 .........
Stage 3 7 5
2494 3730 .........
Stage 4 9 5
6660 10040 .........
Cable number 31016
Maximum speed limitation
R min R max Measured

Measuring device
Maximum speed limitation [Ω] [Ω] value [Ω]
Pin+ Pin- R134 R134 R134
Stage 1 2 5
408 606 .........
Stage 2 4 5
1098 1639 .........
Stage 3 6 5
2477 3710 .........
Stage 4 1 5
6620 9970 .........
Cable number 31016

DEVICE DESCRIPTION
Voltage measurement
– Ignition “ON”
– All jumpers must be closed in the break box. Measurement sequences for "Accelerator monitoring",
"Immobiliser" and "Diagnosis" are also carried out with the jumper open.
– Engine idling
Voltage is measured with the engine running and the vehicle stationary.
The operating voltage is approximately 28 V and the operating voltage range is 16 - 32 V. The current
consumption is > 1 A for manually-operated gearboxes and < 1 A if a fan clutch is connected and there are
no power take-offs. The current consumed by the Power Train Manager, not including consumers, is less
than 0.5 A.
Power supply
Comment: Pin VS/1 is connected to terminal 31 - battery ground.

PTM pin designation
Pin+ Pin- value [V] value [V]
Power supply for Power Train
VS/6 VS/1
Manager - terminal 30 ~= UBat ..........
Power supply for Power Train
VS/3 VS/1
Manager - terminal 15 ~= UBat ..........
Digital inputs
Measured value
Measuring device Setpoint value [V]
[V]
PTM pin designation
Switch Switch Switch Switch
Pin+ Pin-
open closed open closed
External engine stop request
C/19 VS/1
Reverse-gear interlock 0 V ~= UBat .......... ..........
External engine start request
Parking brake relay for start/stop C/7 VS/1
(K266) 0 V ~= UBat .......... ..........

Ignition switch request for engine
start, terminal 50
Steering wheel lock (Q101),
C/17 VS/1
plug conn. Starter interlock 0 V ~= UBat .......... ..........
(X669), starter interlock relay for
refrigerated body (K871)
Intelligent brake request (linking)
C/34 VS/1
Continuous brake button (S1133) 0 V ~= UBat .......... ..........

DEVICE DESCRIPTION
Measured value
[V]
PTM pin designation
Pin+ Pin-
request
C/46 VS/1
switch (S284) 0 V ~= UBat .......... ..........
Closed: Road speed limiter
Open: Cruise control
C/31 VS/1
Power take-off 1 switch (S222) 0 V ~= UBat .......... ..........
C/43 VS/1
Power take-off 2 switch (S223) 0 V ~= UBat .......... ..........
Splitter switch request
Gear selector lever switch
(S477) C/21 VS/1
Closed: Split Low 0 V ~= UBat .......... ..........
Open: Split High
Gear selector lever switch C/12 VS/1
(S477) 0 V ~= UBat .......... ..........

(redundant input)
C/33 VS/1
Gear selector lever switch 0 V ~= UBat .......... ..........
(S477)
Intermediate speed controller 1
request C/23 VS/1
ZDR interface (X1996 pin 2) 0 V ~= UBat .......... ..........

request C/35 VS/1

request C/47 VS/1

Gearbox neutral position
feedback C/48 VS/1
Neutral position switch (S172) ~= UBat 0 V .......... ..........

DEVICE DESCRIPTION
Measured value
[V]
PTM pin designation
Pin+ Pin-
Power take-off display switch
C/44 VS/1
(S219), power take-off switch ~= UBat 0 V .......... ..........
(S222)
Power take-off 2 display switch
C/8 VS/1
(S220), power take-off 2 switch ~= UBat 0 V .......... ..........
(S223)
Engine brake request
Pl. con. for multi-function
steering wheel (X4397 pin 5), C/10 VS/1
continuous brake tip switch ~= UBat 0 V .......... ..........
(A437)
Parking brake feedback
Parking brake check switch C/20 VS/1 Residual
(B369) ~= UBat voltage .......... ..........
< 1 V
Analogue inputs

PTM pin designation
Maximum speed limitation request
ZDR interface (X1996), EDC C/26 VS/1
resistor group (R134) ~= 420 mV ..........

Engine torque limitation request
ZDR interface (X1996), EDC C/37 VS/1
resistor group (R134) ~= 420 mV ..........

Ambient temperature ~= 1.8 V
Temperature sensor, outside air C/1 VS/1 at an
(B269) ambient ..........
temperature
Cable number 60147 31000 of 20°C
temperature B/33 VS/1 ~= 2 V
Oil level sensor (B270) Oil ..........
temperature-dependent
Exhaust gas back pressure signal,
B/21 VS/1
EVB module (Y355) ~= 0.5 V ..........
Cable number blue 31000

DEVICE DESCRIPTION

PTM pin designation
Range-change group change
request
Gear selector lever switch (S477) C/14 VS/1 ~= UBat ..........
– Switch closed ~= 18.8 V ..........
– Switch open
Analogue outputs

PTM pin designation
5 V supply to exhaust gas back
pressure sensor/brake pedal
B/13 VS/1 ~= 0.5 V ..........
sensor
EVB module (Y355)
5 V supply for main fan speed
Fan clutch with speed sensor B/25 VS/1 ~= 5 V ..........
(A968)
Digital outputs
Measured value
PTM pin designation [V]
Pin+ Pin- ON OFF ON OFF
Power take-off 1
Solenoid valve for power take-off A/20 VS/1
1 (Y153) ~= UBat ~= 0 V ........ ........

Power take-off 2
Solenoid valve for power take-off A/21 VS/1
2 (Y154) ~= UBat ~= 0 V ........ ........

range-change group (Y307) ~= UBat ~= 0 V ........ ........

DEVICE DESCRIPTION
PWM outputs
Setpoint value Measured value

Measuring device
PTM pin designation [V] [V]
Pin+ Pin- ON OFF ON OFF
Solenoid valve for High split

position
A/14 A/29
Solenoid valve for splitter box and ~= UBat ~= 0 V ........ ........

Solenoid valve for Low split
position
A/2 A/29
Clutch servo
A/3 VS/1
Clutch servo (Y308) ~= UBat ~= 0 V ........ ........

group, low
A/27 VS/1
group, high
A/39 VS/1
Engine brake
Solenoid valve for engine brake B/37 VS/1
(Y281) ~= UBat ~= 0 V ........ ........

Fan clutch
Fan clutch with speed sensor
B/38 VS/1
(A968) ~= UBat ~= 0 V ........ ........
at a coolant temperature of < 80°C
Torque speed limitation
U min U max Measured

Measuring device
Torque speed limitation [V] [V] value [V]
Pin+ Pin- R134 R134 R134
Stage 1 8 5
0.344 0.495 .........
Stage 2 3 5
0.824 1.14 .........

DEVICE DESCRIPTION

Measuring device
Torque speed limitation [V] [V] value [V]
Pin+ Pin- R134 R134 R134
Stage 3 7 5
1.542 2.001 .........
Stage 4 9 5
2.713 3.201 .........
Cable number 31016
Maximum speed limitation

Measuring device
Maximum speed limitation [V] [V] value [V]
Pin+ Pin- R134 R134 R134
Stage 1 2 5
0.34 0.489 .........
Stage 2 4 5
0.82 1.132 .........
Stage 3 6 5
1.533 1.994 .........
Stage 4 1 5
2.706 3.194 .........
Cable number 31016
Delete diagnostic memory
No more active faults are allowed to be stored in the diagnostic memory once all tests have been performed
and no faults are found!
Before deleting the diagnostic memory, read it out using MAN-cats® II and if it contains any non-diagnosed
faults, these must be archived. Then delete the diagnostic memory.
There must not be any faults in the memory when the ignition is switched back on. Otherwise, search for the
fault and remedy the problem.

DEVICE DESCRIPTION
Measurements with the oscilloscope

Perform the measurement with a Fluke ScopeMeter 123 (oscilloscope).
Frequency input, gearbox speed signal, inductive pickup
Measuring device
PTM pin designation
Pin+ Pin-
B/8 Oscilloscope B/35
Inductive pickup, gearbox input speed (B368)
Measurement is taken between pin B/8 (signal) and B/35 (ground) - inductive pickup, gearbox input speed
(B368).

DEVICE DESCRIPTION
Immobiliser frequency input
Measuring device
PTM pin designation
Pin+ Pin-
Immobiliser data line
B/31 Oscilloscope VS/1
Immobiliser electronics (A477)
Measurement is taken between pin B/31 (data signal) and pin VS/1 (ground) - immobiliser (A477).
Frequency input for fan clutch with speed sensor (A968)
Measuring device
PTM pin designation
Pin+ Pin-
Main fan speed sensor
Measurement was taken at 20°C ambient temperature and with a cold engine.

DEVICE DESCRIPTION
Frequency input for oil level sensor (B270)
Measuring device
PTM pin designation
Pin+ Pin-
Oil sensor ll level - engine oil level
Oil level sensor (B270)
Measurement is taken between pin B/9 (data signal) and pin B/47 (ground) - immobiliser (A477).
Frequency input for accelerator PWM1
Measuring device
PTM pin designation
Pin+ Pin-
Pedal unit 1st input
Accelerator unit (A410)
Measurement is taken between pin B/45 (data signal) and pin VS/1 (ground) - pedal unit 1 (A410).
(1) Accelerator (A410) not pressed

(3) Accelerator (A410) fully pressed

DEVICE DESCRIPTION
Frequency input for accelerator PWM2
Measuring device
PTM pin designation
Pin+ Pin-
Pedal unit 2nd input
Accelerator unit (A410)
Measurement is taken between pin B/10 (data signal) and pin VS/1 (ground) - pedal unit 2 (A410).
Frequency input for clutch displacement sensor (B362)
Measuring device
PTM pin designation
Pin+ Pin-
Clutch displacement sensor signal detection
Clutch displacement sensor (B362)
Measurement is taken between pin B/34 (data signal) and pin VS/1 (ground) - clutch displacement sensor
(B362).

DEVICE DESCRIPTION
CAN data bus
Measuring device
PTM pin designation
Pin+ Pin-
Voltage between driveline CAN High and ground B/6 Oscilloscope VS/1
Cable number/colour Blue/red 31000
Voltage between driveline CAN Low and ground B/18 Oscilloscope VS/1
Cable number/colour Blue/white 31000
Voltage between engine CAN High and ground B/5 Oscilloscope VS/1
Cable number/colour 159 31000
Voltage between engine CAN Low and ground B/17 Oscilloscope VS/1
Cable number/colour 160 31000
CAN data bus for Heavy Duty On-Board Diagnosis
Measuring device
PTM pin designation
Pin+ Pin-
Voltage between HD OBD CAN High and ground B/4 Oscilloscope VS/1
Voltage between HD OBD CAN Low and ground B/16 Oscilloscope VS/1
The diagram shows signal characteristics for the CAN data bus High signal (channel A) and the CAN data
bus Low signal (channel B).

DEVICE DESCRIPTION
LIN data bus
LIN data bus 64512
Measuring device
PTM pin designation
Pin+ Pin-
LIN data bus, multi-function steering wheel - stalk
switch - combined instrument and ground
(1) Stalk switch (3) Combined instrument

(2) Multi-function steering wheel
LIN data bus 64515
Measuring device
PTM pin designation
Pin+ Pin-
LIN data bus, DNR switch and ground B/39 Oscilloscope VS/1
Delete diagnostic memory
No more active faults are allowed to be stored in the diagnostic memory once all tests have been performed
and no faults are found!

DEVICE DESCRIPTION
Before deleting the diagnostic memory, read it out using MAN-cats® II and if it contains any non-diagnosed
faults, these must be archived. Then delete the diagnostic memory.
There must not be any faults in the memory when the ignition is switched back on. Otherwise, search for the
fault and remedy the problem.

ADDITIONAL CIRCUIT DIAGRAMS

BRIEF OVERVIEWS

BRIEF OVERVIEW OF LIN DATA BUS WITH MULTI-FUNCTION STEERING WHEEL, PTM VERSION (TGS/TGX)
07/08
Legend
A100 Central electrical system
A407 Combined instrument
A434 Gearbox DNR switch
A942 Stalk switch for retarder/gearbox
A943 Multi-function steering wheel
A1124 Power Train Manager
F1029 PTM fuse (terminal 15) for switches/sensors
K250 Reverse light relay
X1644 Cab ground point next to central electrical system
X1827 Crimp connector for line 31000
X2002 Pl. con. for B-pillar preselector switch
X4397 Pl. con. Multi-function steering wheel
X4644 Potential distributor for line 60028
——– ————————————————————————
64512 LIN bus, PTM data line – multi-function steering wheel – stalk switch –
combined instrument
64515 LIN bus, PTM data line - DNR switch
——– ————————————————————————
E6 Installation location, central electrical system area
E7 Installation location, control units, plug-in modules
F Installation location, instrument panel
F1 Installation location, middle section
F2 Installation location, steering column/steering wheel
F8 Installation location, gearshift console
H1 Installation location, B-pillar on driver's side

BRIEF OVERVIEW OF LIN DATA BUS WITH MULTI-FUNCTION STEERING WHEEL, PTM VERSION (TGS/TGX)

QUICK OVERVIEW OF LIN DATA BUS WITHOUT MULTI-FUNCTION STEERING WHEEL, PTM VERSION (TGS/TGX)
07/08
Legend
A100 Central electrical system
A407 Combined instrument
A429 Stalk switch for cruise control/gearbox
A434 Gearbox DNR switch
A437 Continuous brake tip switch
F1029 PTM fuse (terminal 15) for switches/sensors
K250 Reverse light relay
X2002 Pl. con. for B-pillar preselector switch
——– ————————————————————————
64512 LIN bus, PTM data line – multi-function steering wheel – stalk switch –
combined instrument
64515 LIN bus, PTM data line - DNR switch
——– ————————————————————————
F Installation location, instrument panel
F8 Installation location, gearshift console
H1 Installation location, B-pillar on driver's side

QUICK OVERVIEW OF LIN DATA BUS WITHOUT MULTI-FUNCTION STEERING WHEEL, PTM VERSION (TGS/TGX)

QUICK OVERVIEW OF POWER TRAIN MANAGER (TGS/TGX) - PAGE 1 OF 3
07/08
Legend
A100 Central electrical system X4644 Potential distributor for line 60028
A302 Central on-board computer V1022 Diode group V783, V818, V921, V922
A410 Accelerator unit Y281 Solenoid valve for engine brake
A407 Combined instrument Y355 for EVB module
A477 Immobiliser ——– ————————————————————————
A1124 Power Train Manager bl blue
B269 Ambient temperature sensor br brown
B369 Parking brake check switch ——– ————————————————————————
F236 Engine control fuse, terminal 15 1 Reverse-gear interlock
F1026 PTM fuse (terminal 30) ——– ————————————————————————
F1027 PTM fuse (terminal 15) B1 Installation location, engine
F1028 PTM fuse (terminal 15) ZDR interface C Installation location, front
G101 Battery 2 E6 Installation location, central electrical system area
K266 Parking brake relay (for start/stop device) E7 Installation location, control units, plug-in modules
K371 Reverse light relay F Installation location, instrument panel
K871 Starter interlock relay for refrigerated body F1 Installation location, middle section
Q101 Steering wheel lock F2 Installation location, steering column/steering wheel
S284 Cruise control/road speed limiter switch F3 Installation location, pedals
S1133 Continuous brake button F4 Installation location, front wall, inside left
X669 Pl. con. for starter interlock F5 Installation location, front wall, inside right
X1544 Pl. con. for frame III G Installation location, battery box
X1547 Pl. con. Door, left R1 Installation location, front frame section
X1559 Pl. con. for engine/EDC/gearbox IV R2 Installation location, rear frame section
X1642 Cab ground point behind combined instrument
X1904 M6 threaded bolt (MP box)
X1966 Pl. con. for ignition lock
X1971 Pl. con. Immobiliser
X1996 Pl. con. for ZDR interface (vehicle management computer/PTM)
X2408 Pl. con. for EVB module
X2541 21-pin potential distributor for line 31000
X3385 Pl. con. for engine brake/EVB


07/08
Legend
A143 ECAS/EFR control unit bl/wt blue/white
A144 Retarder control unit ye yellow
A302 Central on-board computer wt/bl white/blue
A312 Customer-specic control module wt/ye white/yellow
A330 TipMatic control unit (on gearbox) ——– ————————————————————————
A402 EBS control unit B1 Installation location, engine
A435 EDC control unit B2 Installation location, gearbox
A479 ACC control unit E7 Installation location, control units, plug-in modules
A609 LGS control unit F1 Installation location, middle section
A626 Hydrostatic front-wheel drive control unit F3 Installation location, pedals
A968 Fan clutch with speed sensor F4 Installation location, front wall, inside left
A1124 Power Train Manager F8 Installation location, gearshift console
B362 Clutch displacement sensor H1 Installation location, B-pillar on driver's side
B368 Inductive pickup, gearbox input speed
R283 Terminating resistor HD OBD CAN
S172 Gearbox neutral position switch
S477 Gear selector lever switch
X200 Pl. con. for diagnosis (MAN-cats)
X1551 Pl. con. for engine/EDC/gearbox II
X1553 Pl. con. for engine/EDC/gearbox III
X1559 Pl. con. for engine/EDC/gearbox IV
X1604 Pl. con. for switch in gearshift knob
X1948 Pl. con. for engine/gearbox (MP box)
X1972 Pl. con. for pedals, outside
Y307 Valve block
Y308 Clutch servo
——– ————————————————————————
bl blue
bl/rd blue/red


07/08
Legend
A437 Continuous brake tip switch R1 Installation location, front frame section
B270 Oil level sensor
G101 Battery 2
R134 EDC resistor group
S219 Switch, display, power take-off
S220 Switch, display, power take-off II
S222 Switch, power take-off I
S223 Switch, power take-off II
X327 Plug connector to solenoid valve in frame
X656 Pl. con. for cab/frame
X1551 Pl. con. for engine/EDC/gearbox II
X1552 Pl. con. for power take-off I/ADR heating
X1554 Pl. con. for power take-off II/ADR heating
X1557 Pl. con. for frame, left
X1559 Pl. con. for engine/EDC/gearbox IV
X2541 21-pin potential distributor for line 31000
X3462 Pl. con. for engine power take-off
Y153 Solenoid valve for power take-off I
Y154 Solenoid valve for power take-off II
——– ————————————————————————
B1 Installation location, engine
B2 Installation location, gearbox
F4 Installation location, front wall, inside left
F5 Installation location, front wall, inside right
G Installation location, battery box


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Electrical system

Power Train Manager (PTM)

Editorial deadline 02/2012

MAN Truck & Bus AG

We reserve the right to make modications in the course of further development.

© 2012 MAN Truck & Bus AG

Editorial Department: SAWAS-Y, WT, RM, 02/2012

Printing: MAN-Werksdruckerei (on-site printing works)

2 T 160 1st edition

Safety instructions ....................................................................................................... 15

System description ...................................................................................................... 27

Additional circuit diagrams

Brief overviews ......................................................................................................... 137

T 160 1st edition 3

T 160 1st edition 5

Test step list for Power Train Manager (A1124)........................................................................................... 115

6 T 160 1st edition

T 160 1st edition 7

8 T 160 1st edition

EOL End of line (programming)

T 160 1st edition 9

HZA Stop signal system

10 T 160 1st edition

MSG EDC engine control unit

T 160 1st edition 11

12 T 160 1st edition

ZDR Intermediate speed control

T 160 1st edition 13

1. Regulations for preventing accidents leading to injury to personnel

During inspection, adjustment and repair work

Working on the brake system

Working on vehicles with a compressed natural gas (CNG) system

Working on the compressed natural gas (CNG) system

T 160 1st edition 15

Operating the engine

Bodies and special bodies

Working on high-pressure lines

Testing injection nozzles

Work on the vehicle electrical system

Important: battery gases are explosive!

Caution! Battery acid is poisonous and corrosive!

16 T 160 1st edition

Work on plastic tubes – risk of damage and re

Working with a tilted cab

Work on the air-conditioning system

Work on the airbag or belt pretensioner units

T 160 1st edition 17

Working on the independent heating

2. Guidelines for preventing damage and premature wear on units

3. Limited liability for spare parts and accessories

4. Regulations for avoiding injury and environmental contamination

Health protection precautions

18 T 160 1st edition

Service products and process materials

Cleaning the cooling circuit

Cleaning the lter insert

Used engine/gearbox oil

Dealing with AdBlue®

5. Information for working on the Common Rail system