AC System MAN TGA, TGM

Electrical System
Air-conditioning System
Copy deadline: 03.2005
System Description
81.99198-7432 3rd edition T 69
MAN Nutzfahrzeuge Aktiengesellschaft Systembeschreibung T 69, 3. Ausgabe
Dachauer Str. 667 Elektrische Anlage
80995 MÜNCHEN Klimaanlage
oder - Englisch -
Postfach 50 06 20 Printed in Germany
80976 MÜNCHEN
System Description T 69
3rd edition
Electrical System
Air-conditioning System
81.99198-7432
PREFACE / PRINTER’S IMPRINT
PREFACE
This manual is intended to provide assistance in performing repairs correctly on the vehicles and units listed
here.
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 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 must be left to our after-sales service or the after-sales service of the
manufacturer. These components are mentioned specifically in the text.
Important instructions relating to safety and accident prevention are specially highlighted in the text as follows.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed exactly 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.
Best wishes from
MAN Nutzfahrzeuge Aktiengesellschaft
Munich Plant
PRINTER'S IMPRINT
We reserve the right to make modifications in the course of further development.
2005 MAN Nutzfahrzeuge Aktiengesellschaft
Reprinting, copying or translation, even of extracts, is not allowed without the written approval of MAN
Nutzfahrzeuge AG.
All rights under the copyright law are strictly reserved by MAN Nutzfahrzeuge AG.
If any changes are made without the written approval of MAN Nutzfahrzeuge AG then MAN Nutzfahrzeuge
AG shall not be liable for any warranty or guarantee claims arising from damage and defects attributable
to the unauthorised modification. Furthermore, MAN Nutzfahrzeuge AG shall not be liable for any damage
resulting from the unapproved modification.
Redaktion: VSAID-Steyr, HA, 03.2005
Satz: VSAID-Steyr
Druck: MAN-Werksdruckerei
II T 69
TABLE OF CONTENTS
Content Chapter/Page
Index V
Abbreviations VII
Introduction
Safety instructions .................................................................................................... 1 - 1

Model overview ....................................................................................................... 1 - 6
Explanatory notes to the wiring diagrams ........................................................................ 1 - 8
Device description
System description .................................................................................................. 2 - 11

General information ............................................................................................. 2 - 11
Air-conditioning system ......................................................................................... 2 - 11
Functional description .............................................................................................. 2 - 13
Description of components ........................................................................................ 2 - 23
Control element, cab heating with air-conditioning system (A474) ..................................... 2 - 23
High/low-pressure switch on refrigerant tank (B203) ..................................................... 2 - 24
Compressor with magnetic coupling (Y114) ................................................................ 2 - 25
Solenoid valve, air-conditioning system at front end (Y117) ............................................. 2 - 26
Condenser ........................................................................................................ 2 - 27
Temperature sensor, internal air-conditioning (B393) ..................................................... 2 - 28
External temperature sensor .................................................................................. 2 - 29
Evaporator sensor ............................................................................................... 2 - 30
Heat exchanger sensor (blow-out air temperature sensor) .............................................. 2 - 31
Diagnosis ............................................................................................................. 2 - 32
General information ............................................................................................. 2 - 32
SPN list (fault codes) and fault code description, control element ...................................... 2 - 39
Test step list for air-conditioning system ..................................................................... 2 - 43
Additional wiring diagrams
Overviews ............................................................................................................. 3 - 51
Brief overview of the air-conditioning system ............................................................... 3 - 52
wiring diagram No. 81.99192.1380 .............................................................................. 3 - 54
Air-conditioning system wiring diagram ............................................... sheet 1 of 2 ....... 3 - 54
Air-conditioning system wiring diagram ............................................... sheet 2 of 2 ....... 3 - 56
T 69 III
INDEX
Catchword Page
A
Air conditioning, system............................................................................................................................ 2 - 11
B
Brief overview of the air-conditioning system ...........................................................................................3 - 53
C
Compressor with magnetic coupling (Y114)
Components ........................................................................................................................................2 - 25
Function...............................................................................................................................................2 - 17
Condenser
Components ........................................................................................................................................2 - 27
Function...............................................................................................................................................2 - 20
Connection valves ....................................................................................................................................2 - 20
Control element, cab heating with air-conditioning system (A474)
Components ........................................................................................................................................2 - 23
Connector pin assignment...................................................................................................................2 - 14
D
Description of the refrigerant circuit..........................................................................................................2 - 13
Diagnosis socket (X200)...........................................................................................................................2 - 34
Diagnosis socket HD-OBD (X200) ...........................................................................................................2 - 34
E
Evaporator ................................................................................................................................................2 - 20
Evaporator sensor
Components ........................................................................................................................................2 - 30
Function...............................................................................................................................................2 - 15
Explanatory notes to the wiring diagrams...................................................................................................1 - 8
External temperature sensor
Components ........................................................................................................................................2 - 29
Function...............................................................................................................................................2 - 15
F
Filling air-conditioning systems.................................................................................................................2 - 22
Fluid tank ..................................................................................................................................................2 - 18
Function diagram of the refrigerant circuit ................................................................................................2 - 13
G
General information, diagnosis.................................................................................................................2 - 32
General information, system..................................................................................................................... 2 - 11
H
Heat exchanger sensor (blow-out air temperature sensor)
Components ........................................................................................................................................2 - 31
Function...............................................................................................................................................2 - 15
Heater element bypass flap......................................................................................................................2 - 17
High/low-pressure switch on refrigerant tank (B203)
Components ........................................................................................................................................2 - 24
Function...............................................................................................................................................2 - 19
I
Installation positions for diagnosis socket ................................................................................................2 - 36
Installation positions for location identifiers ................................................................................................1 - 9
M
Main functions, diagnosis .........................................................................................................................2 - 37
Model overview...........................................................................................................................................1 - 6
R
Refrigerant circuit and its components .....................................................................................................2 - 12
T 69 V
INDEX
Refrigerant oil fill volume ..........................................................................................................................2 - 22

Refrigerant R 134a ...................................................................................................................................2 - 21
S
Selecting between air-conditioning system modes AC or REHEAT .........................................................2 - 16
Solenoid valve, air-conditioning system at front end (Y117).....................................................................2 - 26
SPN list (fault codes) and fault code description, control element ...........................................................2 - 39
System structure, K-lines..........................................................................................................................2 - 32
T
Temperature sensor, internal air-conditioning (B393)
Components ........................................................................................................................................2 - 28
Function...............................................................................................................................................2 - 16
Test description.........................................................................................................................................2 - 43
Test step list..............................................................................................................................................2 - 44
Test step list for air-conditioning system...................................................................................................2 - 43
Thermostatic expansion valve ..................................................................................................................2 - 19
Troubleshooting program .........................................................................................................................2 - 38
W
Wiring diagram, air-conditioning system...................................................................................................3 - 54
VI T 69
LIST OF ABBREVIATIONS
Abbreviations
A
a Acceleration
ABE General certification
ABS Antilock Braking System
ABV Anti-skid system
AC Air Conditioning
ACC Adaptive Cruise Control
ACK Acknowledge
ADC Analogue-Digital Converter
ADR European agreement for cross-border transport of dangerous goods by road (French title: Accord
européen relatif au transport international des marchandises Dangereuses par Route)
AGB Automatic road speed limiter
AGND Analogue Ground
AGR Exhaust gas recirculation
AHK Trailer coupling
AHV Trailer brake valve
ALB Automatic load balancing
AMA Antenna mast system
ANH Trailer/semitrailer
AS Automatic gearbox
ASD Trailer socket
ASM Trailer control module
ASR Anti-Spin Regulation (traction control)
ASV Trailer control valve
ATC Automatic Temperature Control
ATF Automatic Transmission Fluid
AU Statutory exhaust emission test
AV Exhaust valve
AVS Automatic gear preselection
B
BA Operator’s Manual
BBA Service brake system
BBV Service brake valve
BKR Brake power regulator
BUGH Front heater
BV Backup valve
BVA Brake wear indicator
BVS Brake wear sensor
BVV Brake wear sensor supply
BW German Army
BWG Brake power sensor
BZ Brake cylinder
C
CAN Controller Area Network (data bus system with serial bit transmission)
CAN-H CAN-high data line
CAN-L CAN-low data line
CATS Computer-assisted testing and diagnostic system
CBU Central Brake Unit
CCVS Cruise Control Vehicle Speed
CKD Completely Knocked Down (completely dismantled vehicle)
CNG Compressed Natural Gas
CPU Central Processing Unit
CRT Continuously Regenerating Trap (exhaust muffler, two-way catalytic converter, diesel particulate
filter)
CRC Cyclic Redundancy Check
CS Comfort Shift
T 69 VII
D
DAHL Roof ventilator
DBR Auxiliary brake relay
DECKE Cover (for doors)
DF Speed sensor
DFÜ Data transmission
DIA Diagnosis and information display
DIAK Diagnosis, K-line (data line)
DIAL Diagnosis, L-line (interrogation line)
DIAR Diagnosis, further interrogation
DIN German industrial standard
DKE Throttle valve increase (ASR control)
DKH Roof duct heating
DKL Roof flaps
DKR Throttle valve reduction (reduction request from ASR to EDC/EMS)
DKV Throttle valve specification (load sensor signal from pedal value sensor, EDC/EMS)
DLB Compressed air brake system
DM Diagnostic Message
DNR Drive Neutral Reverse (selector lever switch for automatic)
DPF Diesel Particulate Filter
DRM Pressure control module
DS Pressure sensor
DSV Pressure control valve
DTCO Digital tachograph
DV Throttle valve
DWA Anti-theft warning system
DZG Speed sensor
DZM Rev counter
E
EBS Electronic Braking System
ECAM Electronically Controlled Air Management
ECAS Electronically Controlled Air Suspension
ECE Emergency shut-off to ECE 36
ECU Electronic Control Unit
EDC Electronic Diesel Control
EDM Electronic Diesel consumption Measuring system
EDR Top speed governor
EEC Electronic engine controller
EEPROM Electrically erasable and programmable read-only memory
EFR Electronic shock absorber control (ESAC)
EFS Electric driver's seat
EHAB Electro-hydraulic shut-off device
ELAB Electrical shut-off device
ELF Electronically controlled air suspension
EMS Electronic throttle control (ETC)
EMV Electromagnetic compatibility (EMC)
EOL End-of-line (programming)
EP Injection pump
ER Engine retarder (engine brake)
ESAC Electronic Shock Absorber Control
ESP Electronic Stability Program
ESR Electric sun-blind
EST Electronic control unit
EV Intake valve
EVB Exhaust Valve Brake
F
FAP Driver's area
FAQ Frequently Asked Questions
FBA Parking brake system
VIII T 69
FDR Dynamic handling control

FDF Vehicle data file
FFR Vehicle management computer
FGB Road speed limiter
FGR Road speed governor
FHS Cab
FIN Vehicle identification number (17 digits)
FM Vehicle management
FMI Failure mode identification
FMS Fleet Management Standard (global telematics standard)
FMR Vehicle/engine management
FOC Front Omnibus Chassis (bus/coach chassis with front-mounted engine)
FSCH Windscreen heater
FSG Ground reinforcement system
FSH Window/mirror heating
FTW Driver's partition
FUNK Radio communication unit
FZA Destination system
FZNR Vehicle number (7 digits)
G
GDK Controlled diesel catalytic converter
GEN Alternator
GET Gearbox
GGVS European agreement for cross-border transport of dangerous goods by road (French abbreviation:
ADR)
GND Ground
GP Gearbox planetary gear group (range-change box)
GS Gearbox control
GV Gearbox splitter gear group (splitter box)
H
HA Rear axle
HBA Auxiliary brake system
HGB Maximum road speed limiter
HGS Hydraulic gearshift
HLUE Hydrostatic fan
HOC Rear Omnibus Chassis (bus/coach chassis with rear-mounted engine)
HSS Highside switch
HST Main switch panel
HU Main inspection
Hz Hertz (number of cycles per second)
HZA Bus stop indicator system
HZG Auxiliary speed sensor
I
IBEL Interior lighting
IBIS Integrated on-board information system
IC Integrated Circuit
ID Identification
IMR Integrated mechanical relay (starter control)
INA Information indicator (e.g. check lamp)
IR Individual control (ABS)
IRM Modified individual control (ABS)
ISO International Standards Organisation
IWZ Incremental angle/time measuring system
K
KBZ Combination brake cylinder
KFH Fuel filter heater
KITAS Kienzle intelligent tachograph sensor
KLI Air-conditioning system
T 69 IX
KNEEL Kneeling
KSM Customer-specified control module (control unit for external data exchange)
KSW Customer's special request
KWP Key Word Protocol (protocol for MAN-cats diagnosis)
L
LBH Air reservoir
LCD Liquid crystal display
LDA Manifold-pressure compensator (boost control)
LDF Charge pressure sensor
LDS Air spring/damper system
LED Light emitting diode
LF Air suspension
LGS Lane Guard System
LL Idling speed
LLA Idling speed increase
LLR Idling speed control
LNA Steering trailing axle
LNG Liquefied Natural Gas
LOE Steering oil monitor
LPG Liquefied Petroleum Gas
LWR Headlight beam regulator
LSVA Distance-based heavy vehicle toll
M
M-TCO Modular EU tachograph
MAB Solenoid valve shut-off (engine shut-off by high-pressure solenoid valve in injection pump)
MAN- cats MAN computer-assisted testing and diagnostic system
MAR Solenoid valve shut-off relay (redundant engine shut-off relay)
MDB Engine speed range
MES Quantity positioner
ML Midline
MMI Man-machine interface
MOTB Engine brake
MP Motor power box (cable duct on engine block)
MR Engine governor - ASR
MSG Engine control unit (EDC)
MV Solenoid valve
MZ Diaphragm cylinder
N
n Engine speed
NA Power take-off
NBF Needle movement sensor
NES New Electronic Structure
NFZ Commercial vehicles
NLA Trailing axle
NSL Rear fog lamp
NSW Fog lamp
O
OBDU Onboard Diagnostic Unit (subsystem of central on-board computer)
OC Occurrence count (frequency counter of a fault)
OEAB Oil separator
OENF Oil replenisher
P
p Pressure
PBM Pulse Breadth Modulation (also see PWM)
PLM Programmable Logic Module
PSG Pump control unit (EDC)
PTO Power take-off
X T 69
PWM Pulse Width Modulation (also see PBM)
R
RA Repair Manual
RAH Interior heating
RAM Random Access Memory
RAS Rear Axle Steering
RAS-EC Rear Axle Steering with Electronic Control
RDRA Tyre pressure control system
RDS Radio Data System
RET Retarder
RKL Priority vehicle light
RLV Relay valve
RME Rape seed oil methyl ester (biodiesel)
ROM Read Only Memory
S
SA Special equipment
SAE Society of Automotive Engineers
SAMT Semi-automatic mechanical transmission
SB Service outlet
sec Second
SER Standard/series production
SG Control unit
SH Select-high control (ABS)
SKD Semi Knocked Down
SL Select-low control (ABS)
SML Side marker lights
SPN Suspect Parameter Number
STA Engine start/stop
SWR Headlight cleaning system
T
t Time
TBM On-board telematics module
TC Traction Control
TCM Trailer Control Module
TCO Tachograph
TKU Technical customer document
TMC Traffic Message Channel
TPM Tyre Pressure Module
TRS Technical road transport directives
TSC Torque Speed Control
TSU Tachograph Simulating Unit (vehicles without MTCO/DTCO)
TUER Door control
U
UBat Battery voltage
UDF Conversion file
UDS Crash recorder
V
v Road speed
VA Front axle
VDF Vehicle data file
VG Transfer case
VLA Leading axle
W
WA Maintenance Manual
WAB Water separator
WaPu Water pump Intarder
T 69 XI
WLE Swap-body unit

WR Warning relay
WS Position sensor
WSK Torque converter and clutch unit
Z
z Braking rate/deceleration
ZBR Central on-board computer
ZBRO Central on-board bus computer
ZDR Intermediate speed governor (ISG)
ZE Central electrical system
ZR Central computer
ZS Central lubrication
ZUSH Auxiliary heater
ZWS Time-based maintenance system
λ Slip
µ Coefficient of friction
µC Microcontroller (microprocessor)
XII T 69
INTRODUCTION
INTRODUCTION
SAFETY INSTRUCTIONS
General information
Working with trucks, buses and the accompanying service products should not pose any problems if operators,
maintenance personnel and repair staff receive suitable training.
The following sections include summaries of important regulations listed according to major topics. The
intention is to provide the knowledge needed to avoid accidents which could lead to injury, damage and
environmental pollution. They represent only a small excerpt from the wide range of accident prevention
regulations and cannot replace these. It goes without saying that all other safety regulations must be
followed and that the corresponding action must be taken..
Additional danger warnings appear in the manuals whenever potential risks are involved.
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident involves skin
contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes,
etc.
1. Regulations for preventing accidents leading to injury to personnel
– Secure units during their removal.

– Support the frame when working on the pneumatic or spring suspension system.
– Keep units, ladders, stairs, steps and the surrounding area free from oil and grease.
Accidents caused by slipping can have very serious consequences.
Only authorised technical personnel are entitled to perform inspection,
adjustment and repair work
Working on the brake system

– Perform visual, function and effectiveness checks on the brake system after carrying
out any work on it whatsoever. These checks must be made in accordance with the
safety inspection (SP).
– Check the function of ABS/ASR and EBS systems using a suitable test system (e.g.
MAN-cats).
– Collect hydraulic oil and brake fluid as it drains out.
– Hydraulic oil/brake fluid is poisonous!
Do not allow brake fluid to come into contact with food or open wounds.
– Treat hydraulic oil/brake fluid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.
T 69 1-1
INTRODUCTION
Operating the engine

– Only authorised personnel are permitted to start and operate an engine.
– Do not approach moving parts of a running engine too closely.
Do not wear baggy clothing and tie up or cover long hair.
Ensure adequate ventilation if you are working in enclosed spaces.
– Do not touch units with your bare hands when they are at operating temperature.
Danger of burns!
Always wear protective gloves when changing oil (in units at operating temperature)
in particular.
– Do not open the coolant circuit unless the engine is cool.
Suspended loads
– No-one is allowed to stand under a unit suspended from a crane hook. - Keep all
lifting tackle in good condition -
Working on high-pressure lines

– Do not attempt to tighten or loosen pipe lines and hoses when they are under
pressure (e.g. lubrication circuit, coolant circuit and hydraulic oil circuit).
Fluid spraying out represents an injury hazard!
– Do not hold your hands under the jet of fuel when checking the injector nozzles. Do
not inhale fuel vapours.
Working on the vehicle electrical system

– Always disconnect the batteries before working on the electrical system.
Disconnect the earth cable first and connect it last when reconnecting.
– Measure voltage only using a suitable measurement device.
The input resistance of the measurement device must be at least 10 MΩ.
– Tow-start the vehicle only with the batteries connected (minimum charge 40%)! Do
not use a boost-charger to jump-start the vehicle! Always disconnect the positive
and negative leads before boost-charging batteries.
– Disconnect the batteries and recharge them every 4 weeks if the vehicle is not in
use.
– The ignition must be switched off before the wiring harness plugs of the electronic
control units are disconnected or connected up.
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 this gas may be ignited by sparks produced
by other continuously operating consumers, the tachograph etc. that cannot be
shut down. Blow compressed air through the battery box before disconnecting the
batteries!
– Avoid short circuits caused by polarity reversal or by placing metal objects (spanners,
mole grips, etc.) on the battery terminals.
Caution! Battery acid is poisonous and corrosive!

– Wear appropriate protective clothing (gloves) when handling batteries.
Do not tilt batteries, acid may leak out.
1-2 T 69
INTRODUCTION
Electric welding
– Connect up the "ANTIZAP SERVICE MONITOR" protective device (MAN item
number 80.78010.0002) in accordance with the instructions supplied with the device.
– If this device is not available, disconnect the batteries and connect the positive cable
to the negative cable in order to make a conductive connection.
– Always earth the welding equipment as close as possible to the welding area. Do not
lay the cables to the welding equipment in parallel to electrical cables in the vehicle.
– The chassis is not intended for use as an earth return! If attachments are to be
fitted to the vehicle (e.g. a taillift), additional earth (ground) lines with an adequate
cross-section must be fitted as well. Otherwise the earth connection may be created
along wire cables, wiring harnesses, gearbox shafts, gears etc. Severe damage
could result.
Painting
– If paint spraying is to be carried out, do not expose the electronic components to
high temperatures (max. 95 °C) for more than brief periods; a time of up to 2 hours
is permissible at a maximum of 85 °C. Disconnect the batteries.
Working on plastic tubes - Danger of damage and fire!

– The warning sign opposite is attached to the inside of the diesel fuel or heating oil
tank flap. It warns you against welding or drilling near to plastic tubes.
Working with the cab tilted

– Keep the tilting area in front of the cab clear.
– Keep out of the area between the cab and the chassis during the tilting process. This
is a danger area!
– Always tilt the cab past the tilting point to its final position
Working on the air-conditioning system

– Refrigerants and refrigerant vapours represent a health hazard. Avoid direct contact
and protect your hands and eyes at all times.
– Do not drain gaseous refrigerants in enclosed areas.
– Do not mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant.
2. Notes on preventing damage and premature wear on units

– Only subject units to the load which they have been designed to cope with in accordance with their
designated use. Do not overload them.
– If a fault occurs during operation, determine its cause immediately and correct the problem before the fault
can get any worse.
– Clean the units thoroughly before repairs. Ensure that no dirt, sand or foreign objects can get into the units
whilst carrying out repairs.
– Only use genuine spare parts. Fitting "equivalent parts" made by other companies can lead to severe
damage, and the workshop that did the work will be responsible for it. See the section entitled "Limited
liability for accessories and parts".
– Never run a unit dry, in other words always make sure that it has been filled with oil before running it.
– Never run engines without coolant.
– Apply a suitable information sign to units that are not ready to be operated.
T 69 1-3
INTRODUCTION
– Only use fuels and lubricants (engine oil and transmission fluid as well as antifreeze and anti-corrosion
protection) that have been approved by MAN. Keep your workplace clean.
– Comply with the specified maintenance intervals.
– Do not fill engine/gear oil above the maximum level mark. Do not exceed the maximum permitted operational
tilt.
– Severe damage to the unit could result from failure to follow these regulations.
3. Limited liability for accessories and parts

In your own interests, you are recommended to use only accessories expressly approved by MAN and
genuine MAN parts. The reliability, safety and suitability of these parts and accessories have been determined
specifically for MAN vehicles. Despite constant market observation, we cannot judge the aspects of other
products, nor can we accept responsibility for them – even if they have been officially approved by the German
TÜV technical inspection authorities or some other official body.
Attachments and special bodies

Comply with the safety instructions and regulations issued by the body builder in question if attachments or
special bodies have been fitted. Always follow the instructions in the appropriate MAN Guide to Fitting Bodies
(www.manted.de).
Taking out of operation and storing

The special measures described in MAN Works Standard M 3069 Part 3 apply if buses or trucks are to be
withdrawn from service or stored for a period longer than 3 months.
4. Handling brake pads and similar components

– Harmful dust may be released when brake pads or linings are reworked – in particular when they are
skimmed or ground – and when wheel brakes are blown out.
– Please take the necessary precautionary measures and observe the following safety advice to avoid
possible damage to your health:
– If possible, carry out the work in question in the open or in an area equipped with an efficient ventilation
system.
– If possible, use hand-operated or slow-running tools, equipped with a dust-collector if required.
– Fast-running tools should always be fitted with such devices.
– If possible, wet the workpiece prior to cutting or drilling.
– Dispose of brake pads or linings as hazardous waste in an environmentally sound manner.
5. Regulations for avoiding injury and environmental contamination
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 fluids and rinsing water down the drain if this practice is restricted by specific local
regulations. However, the cleaning fluid and rinsing water must in all cases have been passed through an oil
trap with a sludge trap.
Cleaning the filter insert

When blowing compressed air through the filter insert, make sure the filter dust is collected by a vacuum
or is blown into a dust collection bag. Otherwise, use a respiratory protection mask. Wear suitable rubber
gloves or use a skin barrier cream when washing out the insert, because cleaning agents have aggressive
grease-dissolving characteristics.
Engine/gear oil, filter cartridges, inserts and box-type filters, desiccant cartridges
Only dispose of used oil at an approved collection point or depot. It is extremely important that oil is not poured
down the drain or onto the ground since it can pollute drinking water! Filter inserts, cartridges and box-type
filters (oil and fuel filters, desiccant cartridges for the air dryer) are classified as hazardous waste materials
and must be disposed of properly. Please follow the instructions issued by the relevant local authority.
Used engine/gear oil

Lengthy or repeated skin contact with any type of engine/gear oil removes grease from the skin. This can
cause dry skin, irritation or skin inflammation. In addition to these hazards, used engine oil contains dangerous
materials which have been shown to have a carcinogenic effect in animal skin tests.
1-4 T 69
INTRODUCTION
6. Health protection precautions

– Avoid lengthy, excessive or repeated skin contact with used oils.
– Protect your skin using a suitable skin protection agent or protective gloves.
– Clean areas of skin which have come into contact with engine oil.
– Wash the areas thoroughly with soap and water.
– Use a nail brush to increase the cleaning effectiveness.
– Special cleaning agents make it easier to clean dirty hands.
– Do not use petrol, diesel oil, gas oil, thinners or solvents.
– Apply a greasy skin cream after cleaning your skin.
– Change out of clothing or shoes which have become soaked with oil.
– Never put oil-soaked rags into your clothing pockets.
Take care to dispose of used engine/gear oil properly.
- Oils can damage groundwater quality -
Therefore, never pour used oil onto the ground, into water or down the drains or sewers. Failure to comply
with these instructions can lead to prosecution.
Collect and dispose of used oil carefully. Contact the point of sale, supplier or your local authority for
information about collection depots.
Extract from "Information on dealing with used engine oil"
The Mineral Oil Traders’ Association (MINERALÖLWIRTSCHAFTSVERBAND E.V.) Steindamm 71, D-20099
Hamburg
T 69 1-5
INTRODUCTION
MODEL OVERVIEW
The System Description T 69 (3rd) Air-conditioning System - 03.2005 edition, can be used for the following
vehicles.
Trucknology Generation A (H01-H99)
Model Model designation Model Model designation

HW2 TGA 33.D20 6X4 BB-WW H45 TGA 24.D20 6X2-2 LL-U
H01 TGA 18.D28 4X2 BL-TS H46 TGA 41.D28 8X4 BB-WW
H02 TGA 18.D28 4X2 BB H47 TGA 26/33.D20 6X6H BB
H03 TGA 18.D20 4X2 BB H48 TGA 32.D28 8X4 BB
H05 TGA 18.D28 4X2 BL H49 TGA 32.D20 8X4 BB
H06 TGA 18.D20 4X2 BL H50 TGA 35.D20 8X6H BB
H07 ECT 18.ISM 4X2 BL H51 TGA 18.D28 4X4 BB
H08 TGA 18.D20 4X2 BL-TS H52 TGA 18.D20 4X4 BB
H09 TGA 18.D28 4X2 LL H54 TGA 33.D28 6X6 BB-WW
H10 TGA 18.D20 4X2 LL H55 TGA 26/33.D28 6X6 BB
H12 TGA 18.D28 4X2 LLS-U H56 TGA 26/33.D20 6X6 BB
H13 TGA 18.D20 4X2 LLS-U H57 TGA 40.D28 6X6 BB-WW
H14 TGA 18.D28 4X2 LL-U H58 TGA 40.D20 6X6 BB-WW
H15 TGA 18.D20 4X2 LL-U H60 TGA 19.D28 4X2 BB-WW-SKD
H16 TGA 26.D08 6X2-4 BL H61 TGA 18.D28 4X2 BL-WW-SKD
H17 TGA 26.D28 6X2-2, 6X2-4 BL H62 TGA 33.D28 6X4 BB-WW-SKD
H18 TGA 26.D20 6X2-2, 6X2-4 BL H63 TGA 26.D28 6X4 BL-WW-SKD
H19 TGA 26.D08 6X2-4 LL H68 TGA 40.D28 6X4 BB-WW-CKD
H20 TGA 26.D28 6X2-2, 6X2-4 LL H69 TGA 39.D20 8X2-4 BL
H21 TGA 26.D20 6X2-2, 6X2-4 LL H70 TGA 18.D28 4X4 BL
H22 TGA 18.D20 4X4H BL H71 TGA 28.D28 6X2-4 BL/LL
H23 TGA 26.D28 6X2/2, 6X2/4 BL H72 TGA 26/33.D28 6X6 BL
H24 TGA 26.D20 6X2/2, 6X2/4 BL H73 TGA 35/41.D28 8X6 BB
H25 TGA 26/33.D28 6X4 BB H74 TGA 28.D20 6X2-4 BL
H26 TGA 26/33.D20 6X4 BB H75 TGA 28.D20 6X2-4 LL
H27 ECT 26.ISM 6X2-2, 6X2-4 BL H76 TGA 35/41.D28 8X8 BB
H28 TGA 33.D28 6X4 BB-WW H80 TGA 18.D20 4X4 BL
H29 TGA 26/33.D28 6X4 BL H81 TGA 28.D28 6X4-4 BL
H30 TGA 26/33.D20 6X4 BL H82 TGA 26/33.D20 6X6 BL
H31 ECT 26.ISM 6X2-2, 6X2-4 LL H84 TGA 28.D20 6X4-4 BL
H32 ECT 26.ISM 6X2/2, 6X2/4 BL H85 TGA 28.D20 6X2-2 LL
H33 TGA 40.D28 6X4 BB-WW H86 TGA 28.D28 6X2-2 BL
H34 TGA 40.D20 6X4 BB-WW H87 TGA 28.D28 6X2-2 LL
H35 TGA 26.D20 6X4H BL-2, 6X4H-4 BL H88 TGA 35.D28 8X2-4, 8X2-6 BL
H36 TGA 35.D28 8X4 BB H89 TGA 28.D20 6X2-2 BL
H37 TGA 35.D20 8X4 BB H90 TGA 35.D20 8X2-4, 8X2-6 BL
H38 TGA 41.D28 8X4 BB H91 TGA 35.D28 8X4-4 BLL
1-6 T 69
INTRODUCTION

H39 TGA 41.D20 8X4 BB H92 TGA 35.D20 8X4-4 BLL
H40 TGA 32/35.D28 8X4 BL H93 TGA 35/41.D20 8X6 BB
H41 TGA 32/35.D20 8X4 BL H94 TGA 41.D28 8X4/4 BB/BL (heavy-duty tractor)
H42 TGA 26.D20 6X4H BL/2, 6X4H/4 BL H95 TGA 41.V10 8X4/4 BB/BL (heavy-duty tractor)
H43 TGA 19.D28 4X2 BBS-WW H96 TGA 35/41.D20 8X8 BB
H44 TGA 24.D28 6X2-2 LL-U H99 TGA 28.D20 6X2-4 LL-LOW ENTRY
Trucknology Generation L (N01-N99)

N01 TGL 7,5.D08 4X2 BB (R4) N11 TGL 7,5.D08 4X2 BL (R4)
N02 TGL 8.D08 4X2 BB (R6) N12 TGL 8.D08 4X2 BL (R6)
Trucknology Generation M (N01-N99)

N08 TGM 18.D08 4X2 BB (R6) N34 TGM 13.D08 4X4 BL-FW (R6)
N16 TGM 15.D08 4X2 BL (R6) N36 TGM 13.D08 4X4 BL (R6)
N18 TGM 18.D08 4X2 BL (R6) N38 TGM 18.D08 4X4 BB (R6)
N26 TGM 15.D08 4X2 LL (R6) N48 TGM 26.D08 6X4 BB (R6)
N28 TGM 18.D08 4X2 LL (R6)
T 69 1-7
INTRODUCTION
EXPLANATORY NOTES TO THE WIRING DIAGRAMS
1 Electrical component designation 7 Plug connection (example: 1-pin plug

(example: diode V100 on the central connection X104)
electrical system, number 53) 8 Installation location of the component
2 Installation position on the front of the (see: identifications of installation
central electrical system (here: stamped positions)
number 53) 9 Current path (numbered from 1 to 55/60
3 Installation position on the rear of the on each diagram)
central electrical system (here: connector
78, connection 8)
4 Cable designation, number, with
abbreviated colour name in the case of
coloured cables, cross section information
only given if different from 12
5 Cable designation, number in brackets:
conductor pathways on a p.c.b.
6 Line interruption with information about
where the line continues, with sheet
number (here: sheet 2 – not page number)
and path number (here: path 4)
1-8 T 69
INTRODUCTION
Installation positions for location identifiers
Installation positions for left-hand drive vehicles (TGL/TGM/TGA)
A Rear of vehicle H2 A-pillar, driver's side

B1 Engine J1 B-pillar, co-driver's side
B2 Gearbox J2 A-pillar, co-driver's side
C Front of vehicle L Ceiling/roof
C1 Bumper N Front axle
C2 Entrance, right P Rear axle
C3 Entrance, left R1 Front frame sections
E6 Area of central electrical system R2 Rear frame section
E7 Control unit plug-in modules S1 Door, left
E8 Back wall of cab S2 Door, right
F Dashboard
F1 Mid-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 Shift console
G Battery box
H1 B-pillar, driver's side
T 69 1-9
INTRODUCTION
Installation positions for right-hand drive vehicles (TGL/TGM/TGA)
A Rear of vehicle J2 A-pillar, driver's side

B1 Engine L Ceiling/roof
B2 Gearbox N Front axle
C Front of vehicle P Rear axle
C1 Bumper R1 Front frame sections
C2 Entrance, right R2 Rear frame section
C3 Entrance, left S1 Door, left
E6 Area of central electrical system S2 Door, right
E7 Control unit plug-in modules
E8 Back wall of cab
F Dashboard
F1 Mid-section
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 Shift console
G Battery box
H1 B-pillar, co-driver's side
H2 A-pillar, co-driver's side
J1 B-pillar, driver's side
1 - 10 T 69
DEVICE DESCRIPTION
DEVICE DESCRIPTION
SYSTEM DESCRIPTION
General information
The climate required inside motor vehicles is determined by the people and goods carried in the vehicle.
Particular attention should be paid to the driver of the vehicle from a road safety point of view. The ability of a
person to concentrate is negatively affected by poor atmospheric conditions such as high temperatures, high
atmospheric humidity and pollution caused by dust, noise and odours. These effects can be largely negated
by passing the internal air through a climate control system.
Air-conditioning system
Air-conditioning systems are installed in vehicles in order to provide a pleasant climate for drivers and
passengers in conjunction with the heating and ventilation system. Other advantages of the air-conditioning
system relate to its properties of cleaning and drying the air entering the interior of the vehicle. This has the
side effect of enabling a fogged-up windscreen and windows to be demisted more rapidly.
The following additional characteristics differentiate the controlled air-conditioning system from the
heater:
– A motor-actuated heater element bypass flap provides temperature-controlled air from the ventilation
nozzles
– The air outlet temperatures and the air volume are controlled according to the ambient temperature and the
nominal value selected by the driver
– The air-conditioning control is integrated in the control element and only has to be electrically connected to
the vehicle electrical system
– A high-performance heater blower with motor and adapted, infinitely variable blower controller
– The evaporator with expansion valve and de-icer are integrated in the filter housing for the air-conditioning
system with condensation drain
– A pollen filter (hybrid filter comprising filter mat and activated charcoal) is installed on the inlet side of the
evaporator. This filters particles, gases and odours out of the air and permanently absorbs a proportion of
them. The filter system functions both in fresh air and recirculating air modes.
– The external temperature sensor is integrated in the vicinity of the fresh air induction port
– The electrical connection between the heater and filter housing is made using 2 waterproof plug connections
providing reliable contact
T 69 2 - 11
DEVICE DESCRIPTION
Refrigerant circuit and its components
1 Evaporator 4 Condenser
2 Expansion valve 5 Compressor
3 Fluid tank with dryer
When the vehicle’s engine is running and the air-conditioning system is switched on, the refrigerant
circulates through components (1) to (5) that are connected together by hoses and pipelines. The refrigerant
continuously changes between liquid and gaseous states in this process. Heat is extracted from the air
flowing through the evaporator. The cooled air is distributed to the interior of the vehicle by the heating and
ventilation system.
The required volume of refrigerant is controlled by the expansion valve.
2 - 12 T 69
DEVICE DESCRIPTION
FUNCTIONAL DESCRIPTION
Function diagram of the refrigerant circuit
1 Evaporator 10 Solenoid valve, air-conditioning system at

2 Expansion valve front end (Y117)
3 High/low-pressure switch on fluid tank 11 Internal air-conditioning temperature
(B203) sensor (B393)
4 Valve – Liquid fill only on pressure side 12 External temperature sensor
(large valve diameter) 13 Heat exchanger sensor
5 Fluid tank with dryer 14 Pushbutton switch, air-conditioning
6 Condenser system
7 Compressor with magnetic coupling 15 Control element, cab heating (A474)
(Y114) a High pressure – fluid
8 Valve – Gaseous fill only on induction side b High pressure – gaseous
(small valve diameter) c Low pressure – fluid
9 Evaporator sensor d Low pressure – gaseous
Description of the refrigerant circuit

The air-conditioning system operates according to the principle of the compression refrigeration system in
which the circulating refrigerant is first compressed in gaseous form, then condensed by the dissipation of
heat and finally re-evaporated by reducing the pressure with the application of heat.
When the refrigerant circuit is set in operation, i.e. the air-conditioning system is switched on using the
“air-conditioning system pushbutton switch” (14) when the vehicle’s engine is running, the compressor (7)
draws cold gaseous refrigerant from the evaporator (1). Refrigerant is compressed, during which process it is
T 69 2 - 13
DEVICE DESCRIPTION
heated to about 65 – 105 °C. After this, it is pumped into the condenser (6). There, the hot, compressed gas is
cooled by the slipstream. The gas condenses when the dew point is reached (this depends on the pressure,
e.g. 50 °C at 13 bar pressure for refrigerant R 134a). The resulting liquid refrigerant passes through the fluid
tank (5) and is dried as it does so. Any moisture or impurities are filtered out by the integrated desiccant
insert.
At a pressure of about 2 bar, the high/low-pressure switch on the fluid tank (B203) interrupts the circuit to
the compressor magnetic coupling (7). This means the compressor is immediately decoupled if there is a
pressure loss in the system. The pressure switch also switches off the compressor via the magnetic coupling
if the system overheats, e.g. poor heat dissipation from the condenser (condenser contaminated), which
would result in a pressure of about 26 bar in the system. The refrigerant under high pressure continues to
flow from the fluid tank (5) to the expansion valve (2). It is sprayed into the evaporator (1) at the expansion
valve (low-pressure section). Here, the liquid refrigerant expands and evaporates while absorbing heat. The
heat of vaporisation needed for this is taken from the air flowing past the evaporation vanes. As a result, this
air is cooled and can be used for cooling the inside of the vehicle. The refrigerant is now once again in a
completely gaseous state and is drawn in again by the compressor (7). The cycle starts over again.
Connector pin assignment
Plug X1
Pin Line no. Circuit Designation

1 58000 Input Electrical power supply terminal 58 – lighting
2 —– —– Not used
3 23309 Output Solenoid valve, air-conditioning system at front end (Y117 pin 2)
4 23112 Input Internal air-conditioning temperature sensor (B393 pin 5)
2 - 14 T 69
DEVICE DESCRIPTION

5 59104 Input Engine start signal from central computer 2 (A302 pin F2/17)
High/low-pressure switch on refrigerant tank (B203), magnetic
6 23101/23300 Output
coupling on compressor (Y114)
7 58300 Input Electrical power supply terminal 58D – dimmed lighting
8 31012 Output Earth, internal air-conditioning temperature sensor (B393 pin 6)
Diagnosis, K-line heater and air-conditioning system control
9 24201/16202 Input/output
Diagnosis socket (X200)
Voltage supply, terminal 15
10 25009 Input
Fuse, heater blower/air-conditioning system (F397)
Ground, terminal 31
12 31000 Input
Central electrical system (A100 pin G/2)
Plug X2

1 Red Output Electrical power supply blower terminal 15 – sequence controller
2 Green Input Diagnostic checkback, blower controller
3 Brown Output Earth blower terminal 31
4 Yellow/green Input Evaporator sensor
Checkback evaporator sensor, external temperature sensor, heat
5 Red/white Output
exchanger sensor
6 Yellow Output Fresh air/recirculating air flap motor connection A
7 White/red Input Checkback potentiometer heater element bypass flap
9 Grey Output Fresh air/recirculating air flap motor connection B
10 Black Input Heat exchanger sensor
11 Black/white Output Reference voltage 5 V
12 Yellow/black Output Heater element bypass flap motor connection A
13 White/yellow Input External temperature sensor
14 Violet Output Voltage blower control
15 Grey/red Output Heater element bypass flap motor connection B

The measured external temperature provides the basic parameter used in the control function. Further
adaptation of the heating/cooling power and the blower is then performed using the other sensors.
Evaporator sensor
The evaporator sensor measures the evaporator temperature and is used for regulating the required cooling
power. No regulation takes place at temperatures below 0 °C, to protect against icing. This is done by
switching the refrigerant compressor off and on.

The electronic control unit calculates a blow-out air temperature depending on the required heating power.
This temperature is set by activating the water timing valve by means of a water flow volume control.
T 69 2 - 15
DEVICE DESCRIPTION
Internal air-conditioning temperature sensor (B393)
Pin Line no. Designation

1 23335 Blower motor +24 V – X1560 relay socket
2 31000 Blower motor earth – X2541 potential distributor 21-pin line 31000
3 and 4 —– Not used
NTC 10 kΩ – Cab heating control element with air-conditioning system at
5 23112
about 25 °C
NTC 10 kΩ – Cab heating control element with air-conditioning system at
6 31012
about 25 °C
Nominal/actual value comparison: The internal air-conditioning temperature sensor measures the actual
internal temperature. This control parameter is the most important one, since it is the only one that measures
the ambient conditions for the driver. The internal temperature influences all automatically controllable heating
components (solenoid valve air-conditioning at front-end, magnetic coupling compressor, blower).
Setting the nominal value: Nominal values from 16 °C to 32 °C can be set for the internal temperature. The
nominal value set on the control element is also corrected by the control system depending on the external
temperature. A higher internal temperature is set when the external temperature is low and vice versa. The
middle position (internal temperature dial, item 22) is felt to be comfortable by a majority of users (subjective
assessment). The monitoring (MAN-cats) displays 24 °C.
The left side of the dial (which must be turned to the last stop) switches the heating off and sets the
air-conditioning system to maximum power. The right side of the dial (which must also be turned to the last
stop) sets the heating to maximum power and switches the air-conditioning system off. The automatic blower
control continues to be adjusted depending on whether 16 °C or 32 °C is set.
Selecting between air-conditioning system modes AC or REHEAT

In AC, the air-conditioning system is controlled according to the variable evaporator temperature. This means
the temperature of the air emerging from the air-conditioning system at the heat exchanger sensor and in the
interior is controlled by the switch-on time of the compressor or by cycling the water valve. In this setting, the
air-conditioning control automatically switches between cooling, ventilating and heating. At moderate external
temperatures when the air is moist, the humid air may cause the climate inside the cab to be uncomfortable
in spite of the fact that the selected internal temperature is being maintained. Select REHEAT in this case. In
REHEAT, the AC system is set to evaporator temperatures between 2 and 7 °C while the internal temperature
is set by additional heating. Cooling causes some of the humidity in the air to condense out and escape
through the water drain. Subsequent heating means the air inside the cab will be dryer. The REHEAT setting
can also be used at external temperatures up to about 5 °C for demisting the windows more rapidly. AC
control consumes less fuel than REHEAT because the compressor switches on less frequently.
2 - 16 T 69
DEVICE DESCRIPTION
Heater element bypass flap
The bypass flap (1) makes it possible to have a parallel air flow that is not passed over the heating system’s
heat exchanger. The flap is fully opened when the air-conditioning system is operating in order to allow
the greatest possible air flow rate. The flap is closed during REHEAT mode in order to allow for even
dehumidifying. During heating mode, the flap position is infinitely variably controlled depending on the required
heat output (full heating power = flap closed / heating off = flap fully open). This means additional fresh air
is directed to the central nozzles. As a result, the temperature distribution in the cab is improved (warm feet
– cool head). The direct admixture of fresh air at the central nozzles means that they are subject to greater
temperature fluctuations than the other air outlets.

The compressor installed in the vehicle provides the drive for the air-conditioning system and represents one
of the boundaries between the high and low-pressure sides of the refrigerant circuit. The compressor draws
cold refrigerant gas from the evaporator (on the low-pressure side) and compresses it. This process causes
the refrigerant to heat up, after which it is pumped into the condenser (high-pressure side).
The magnetic coupling (Y114) switches the compressor on and off.
Magnetic coupling switched off
1 Belt sheave
2 Electromagnet
3 Anchor plate
4 Spring plate
T 69 2 - 17
DEVICE DESCRIPTION
Magnetic coupling switched on
Fluid tank
Fig. TGL/TGM
The fluid tank (1) is integrated in the condenser.
Fig. TGA
From the condenser, the refrigerant flows into the fluid tank (1) in which a reserve of refrigerant is held in
readiness to compensate for variations in the demand for refrigerant by the evaporator. The built-in fluid tank
is on the high-pressure side of the refrigerant circuit and installed after the condenser. The job of the fluid
tank is to collect the liquid refrigerant from the condenser and to bind up any moisture which the refrigerant
may contain.
2 - 18 T 69
DEVICE DESCRIPTION
A high/low-pressure switch (1) is installed after the fluid tank in order to monitor or limit the pressure conditions
in the enclosed refrigerant circuit.
This pressure switch (1) switches off the compressor via the magnetic coupling if the pressures in the system
are at impermissible levels, thereby protecting the system against follow-on damage.
If the system pressure is less than about 2 bar, as can be caused for example by insufficient refrigerant in the
circuit, the high/low-pressure switch opens and switches off the compressor. If the system pressure rises very
high, as can be caused for example by a contaminated condenser, the high/low-pressure switch switches the
compressor off at about 26 bar.
Thermostatic expansion valve

The thermostatic expansion valve also forms one of the boundaries between the high and low-pressure
parts of the refrigerant circuit. It is installed in front of the evaporator and configured as a block valve. The
expansion valve (also referred to as the injector valve) ensures the optimum amount of refrigerant is injected
into the evaporator. The injection system is a closed-loop control system.
This control loop is formed by the interaction of:

– pressure of the temperature sensor
– low pressure at the evaporator output
– spring pressure
The following applies when the system is in equilibrium: Pressure of temperature sensor = Low pressure at
evaporator output + spring pressure
1 Pressure sensor 6 Spring

2 Diaphragm A To compressor
3 Temperature sensor B From evaporator
4 Pin C From condenser
5 Ball D To evaporator
The compressor draws in the refrigerant and the pressure in the evaporator therefore drops. This low pressure
acts on the diaphragm (2) and pulls it downwards. This movement is transmitted via the pin (4) to the ball (5).
T 69 2 - 19
DEVICE DESCRIPTION
This opens the valve aperture against the spring pressure and the pressurised liquid refrigerant flows into
the evaporator where it can evaporate. Once the refrigerant has flowed through the evaporator and through
the expansion valve, the medium in the temperature sensor (3) picks up the low temperature resulting from
evaporation and contracts (reduction in volume). This means the pressure in the temperature sensor is
reduced. The temperature sensor and the pressure sensor (1) are filled with a medium. The medium is a
liquefied gas or adsorbent which liberates gas when there is a rise in temperature. This causes the balance
of forces on the ball (5) to change, and the ball is then pressed upwards by the spring pressure. The injection
volume is thereby reduced slightly until the forces are once again in equilibrium.
This governing system of the thermostatic expansion valve guarantees superheating of the refrigerant.
Refrigerant superheating is understood to mean the difference between the theoretical evaporation
temperature at the particular pressure and the temperature measured after the evaporator (sensor
temperature). The overheating setting for this expansion valve is 2.8°C. This mechanism prevents too much
refrigerant from being injected into the evaporator since this would mean that not all the refrigerant can
evaporate. Under these circumstances, the compressor would drawn in some liquid refrigerant and could
be damaged by fluid knocks.
Evaporator
1 Evaporator 3 Intake line

2 Injector tubes 4 Expansion valve
The evaporator is installed in the housing of the air-conditioning system directly after the intake openings for
fresh air or recirculating air. Its function is to cool down and dry the warm air in order to control the climate
inside the vehicle. The evaporator is the second heat exchanger in the refrigerant circuit.
The evaporator is a six-row unit in a full aluminium design. The liquid refrigerant is injected into the first row of
the evaporator through the expansion valve and a total of 6 injector tubes. There it expands and can evaporate
whilst absorbing heat. The necessary heat of vaporisation is taken from the air flowing past the evaporator
vanes. The air then cools down and sheds moisture. The humidity which condenses on the evaporator vanes
is allowed to drain out of the system through a condensation drain. The minimum evaporator temperature is
restricted to about +2 °C in order to prevent icing of the evaporator vanes.
Condenser
The function of the condenser is to liquefy the warm refrigerant gas and cool it down. It is arranged in the
vehicle so that the passing slipstream or the air flow from the engine fan provides a good cooling effect.
The compressor pumps hot refrigerant gas at a temperature of 60 – 100 °C into the serpentine pipe system of
the condenser. The large number of condenser vanes forms a large surface area and therefore guarantees a
good exchange of heat. The hot gas dissipates its heat to the slipstream and condenses when its temperature
reaches a level which is dependent on the pressure (dew point). The liquid refrigerant emerges from the
condenser and is pumped on to the liquid tank.
Connection valves
The system can be filled with refrigerant or drained via the connection valves. Pressure gauges can be
connected in order to check the system. The connection valves are configured as needle valves.
2 - 20 T 69
DEVICE DESCRIPTION
1 Coupling element 2 Needle valve
There are different sizes of connection valve in order to avoid mix-ups between connection valves.
Fig. TGL/TGM
Fig. TGA
1 Small valve: Intake side – low-pressure 2 Large valve: Pressure side –

side high-pressure side
The connection valves are located behind the front cover. The plugs have to be removed from the connection
valves.
Refrigerant R 134a
The medium used for the evaporation process in air-conditioning systems is a substance with a low boiling
point. It is referred to a refrigerant. It is known that water, for example, boils at lower temperatures the lower the
pressure. All homogeneous liquids behave in the same way. Reducing the pressure has the effect of reducing
the boiling point, and vice versa. The refrigerant (tetrafluoroethylene) R 134a is a partially halogenated
T 69 2 - 21
DEVICE DESCRIPTION
substance from the group of fluorocarbon compounds (chemical formula CF3CH2F), with a boiling point at
26.5 °C. Partially halogenated substances only have a brief existence in the atmosphere. Since they do
not contain chlorine, they do not attack the ozone layer. Furthermore, their contribution to the greenhouse
effect is relatively slight. Refrigerant R 134a is colourless and has a slight odour of ether. Highly irritant
decomposition products (vapours) can result in contact with fire or hot surfaces. The substance can form an
explosive mixture with air. It decomposes to form hydrohalogens and carbonyl halides. Concentrations of R
134a in the atmosphere which are significantly in excess of the TLV can have an anaesthetic effect.
TLV value: Threshold Limit Value for concentration of substances in the air, e.g. 1000 ml/m³. Inhaling the
decomposition products of R 134a in high concentrations can lead to shortage of breath. Evaporation of the
refrigerant on the skin leads to freezing at the points of contact.
Maintenance note
Various manufacturers offer recycling devices for maintaining and repairing air-conditioning systems filled
with R 134a. These are used for evacuating the refrigerant circuit, recycling and checking the refrigerant and
refilling the circuit. This ensures that the used refrigerant can be completely re-used. It must not be vented
into the atmosphere.
Refrigerant oil fill volume

The oil required for lubricating the refrigerant compressor is in the circuit with the refrigerant and collects in
the components when the system is inoperative. As a result, whenever components are renewed together
with the refrigerant, a small quantity of oil must always be added as well.
Make sure that only oils authorised for use with the relevant refrigerants and systems are filled. Never mix
different oils.
Air-conditioning system oils are hygroscopic, meaning that they absorb moisture from the water vapour in the
air. As a result, never store air-conditioning system oil in open containers!
Topping up after repairs or renewing components

– Refrigerant compressor: Flush the system to remove a large proportion of the residual oil. The basic oil fill
of the new compressor is sufficient, there is no need to add extra oil.
– Condenser: 20 cm3
– Refrigerant tank: 10 cm3
– Evaporator: 30 cm3
– Refrigerant hoses: 10 cm3 per metre
– In case of sudden drainage of the system, e.g. burst hose: 50 cm3
Filling air-conditioning systems

1 Extract the fluid from both sides of the system via the high-pressure and low-pressure lines
2 Drain the used oil
3 Evacuate the system (minimum 30 minutes)
4 Check the vacuum
5 Fill the system via the high-pressure line (refer to the Maintenance Recommendations or Operator’s Manual
for information about the fill volume). The volume in filler hoses can be ignored!
6 After filling, draw the residual fluid in the high-pressure hose into the system using low pressure.
Important! Comply with the following procedure when doing this:

– Close both stop valves (high pressure, low pressure) on the control panel.
– Start the engine, switch on the air-conditioning system.
– Pressure-test the system using the high-pressure and low-pressure gauges on the control panel.
– Close the service connection on the high-pressure side.
– Slowly, one after the other, open the low-pressure and high-pressure stop valves on the control panel
(this draws the remaining volume into the system)!
– Close the service connection on the low-pressure side.
– Disconnect both hoses.
2 - 22 T 69
DEVICE DESCRIPTION
DESCRIPTION OF COMPONENTS
Design
1 Side window ventilation dial 5 Blower dial (S547)

2 AC-ON pushbutton switch (S544) 6 Air distribution dial
3 Internal temperature dial (S546) 7 “REHEAT” pushbutton switch
4 Pushbutton switch, fresh air/recirculating (de-humidify) (S545)
air (S123)
Installation position
The control element for the cab heating and air-conditioning system (1) is located in the instrument panel.
T 69 2 - 23
DEVICE DESCRIPTION
Design
The high/low-pressure switch is installed on the outflow end of the fluid tank.
Installation position, TGL/TGM
Installation position, TGA
The high/low-pressure switch (1) is located on the front left bulkhead.
2 - 24 T 69
DEVICE DESCRIPTION
Design
1 Belt sheave 2 Magnetic coupling
The compressor with magnetic coupling (1) is located on the right-hand side of the vehicle.
T 69 2 - 25
DEVICE DESCRIPTION
Solenoid valve, air-conditioning system at front end (Y117)
Design
A Direction of flow B “RED” cable: Chamber 1; “BROWN”

cable: Chamber 2
Installation position, TGL/TGM
Installation position, TGA
The solenoid valve for the air-conditioning system at the front end (1) is located on the front left bulkhead.
2 - 26 T 69
DEVICE DESCRIPTION
Condenser
Design
The condenser liquefies or cools the hot refrigerant gas.
The condenser (1) is located on the inlet side of the radiator.
T 69 2 - 27
DEVICE DESCRIPTION
Temperature sensor, internal air-conditioning (B393)
Design
The internal air-conditioning temperature sensor measures the actual internal temperature.
The internal air-conditioning temperature sensor (1) is located behind the console in the central part.
2 - 28 T 69
DEVICE DESCRIPTION
Design
The external temperature sensor measures the external temperature.
The external temperature sensor (1) is installed in the bottom part of the blower behind the front cover.
T 69 2 - 29
DEVICE DESCRIPTION
Evaporator sensor
Design
The evaporator sensor measures the evaporator temperature.
The evaporator sensor (1) is located in the evaporator.
The evaporator sensor is shown slightly pulled out in the diagram for ease of interpretation.
2 - 30 T 69
DEVICE DESCRIPTION
Design
The electronic control unit calculates a blow-out air temperature depending on the required heating power.
The heat exchanger sensor (1) is located in the air-conditioning system blower.
T 69 2 - 31
DEVICE DESCRIPTION
DIAGNOSIS
General information
Most control units testable using MAN-cats are connected with diagnosis socket X200 pin 3 / 4 via a K-line.
The diagnostic system stimulates a specific control unit via the K-line. The control unit replies and digitally
transfers the faults stored in the fault memory via the K-line.
"KWP-on-CAN" control units such as TBM and ECAS2 do not have a K-line. Control units with KWP-on-CAN
diagnosis are stimulated by the vehicle management computer K-line. The vehicle management computer
opens a gateway to the control unit in question via the CAN.
System structure of K-lines
TGL/TGM
A302 Central on-board computer 2 (ZBR2) X2544 Potential distributor, 21-pin, K-line
A312 Customer-specified control module
A330 Gearbox control, Tipmatic/AS-TRONIC
A403 Vehicle management computer
A407 Instrumentation
A435 Electronic diesel control
A451 Door module, driver side
A452 Door module, co-driver side
A474 Air-conditioning system
A483 Auxiliary air heater
A494 Auxiliary water heater
A590 Control unit, EMOS (on gearbox)
A.. . Further systems can be networked
X200 Diagnosis socket
2 - 32 T 69
DEVICE DESCRIPTION
TGA
A143 Electronically controlled air suspension A486 Control unit, airbag

(ECAS) A494 Auxiliary water heater
Note: ECAS2 has KWP-on-CAN A688 Additional vehicle computer (for
diagnosis heavy-duty tractor only)
A144 Control, retarder / Intarder A713 Control unit in distributor unit
A266 Control unit, torque converter and clutch A.. . Further systems can be networked
system/retarder X200 Diagnosis socket
A302 Central on-board computer 2 (ZBR2) X2544 Potential distributor, 21-pin, K-line
A312 Customer-specified control module
A330 Gearbox control, Tipmatic/AS-TRONIC
A402 Electronic braking system
A403 Vehicle management computer
A409 Electronically controlled air management
A435 Electronic diesel control
A451 Door module, driver side
A452 Door module, co-driver side
A474 Air-conditioning system
A479 Control unit, ACC
A483 Auxiliary air heater
T 69 2 - 33
DEVICE DESCRIPTION
Diagnosis socket (X200)

The SPN fault codes can be downloaded from the fault memory of various control units using MAN-cats II
(connection on diagnosis socket X200). The results are displayed on the MAN-cats display.
View of socket X200, line side
A Arrow in middle points to pin 1
Diagnosis socket X200 Address

Pin Function Terminal Line number from ZE Pin
Option: HD-OBD
1 not used (186)
CAN High
Option: HD-OBD
2 not used (185)
CAN Low
via X2544 to the
4 K-line KWP 2000 16202
control units
Earthing point, central
9 Negative potential 31 31000 electrical system,
X1644 via X1829
10 Voltage supply 30 30009 via X1535 to fuse F412 / 10A A2/11
11 Voltage supply 15 16000 via X1833 to fuse F376 / 10A F/3
12 Signal, alternator W 59101 Alternator G102 pin 1
Diagnosis socket HD-OBD (X200)

As of 01.01.2005, all vehicles with Euro 4 engines are legally required to have a standardised diagnosis
interface to ISO 15031-3.
In the case of MAN vehicles, the required HD-OBD diagnosis socket will be introduced into production for
the first vehicles from 01.10.2004 (not for all vehicles at the same time). HD-OBD stands for Heavy Duty On
Board Diagnosis. Heavy-duty here in the sense of heavy-duty commercial vehicles.
The installation position and the position designation (X200) remain unchanged as this diagnosis socket
replaces the previous one.
2 - 34 T 69
DEVICE DESCRIPTION
Table for connector pin assignment
Pin Line number Function

1 59101 Speed signal, alternator, term. W
2 —- Not used
3 16202 K-line
4 31000 Ground, terminal 31
5 —- Not used
6 186 HD-OBD-CAN high
7 —- Not used
8 16000 Voltage supply, terminal 15
9 - 13 —- Not used
14 185 HD-OBD-CAN low
15 —- Not used
16 30009 Voltage supply, terminal 30
Adapter cable, HD-OBD
There is an adapter cable available for MAN-cats applications. This cable can be ordered by quoting item
number 07.98901-0002 using the "MAN-cats II - spare parts" order form. All newly ordered diagnosis systems
come with the adapted cable supplied as standard.
T 69 2 - 35
DEVICE DESCRIPTION
Installation positions for diagnosis socket
TGL/TGM
The diagnosis socket X200 (1) is located behind a cover below the cup holder on the co-driver's side.
TGA - old version
The old installation position for the diagnosis socket X200 (1) is on the rear side of the central electrical
system.
TGA - new version
The new installation position for the diagnosis socket X200 (1) is behind a cover below the cup holder on the
co-driver's side.
2 - 36 T 69
DEVICE DESCRIPTION
Diagnosis socket HD-OBD (X200) for TGA and TGL/TGM
The installation position and the position designation (X200) remain unchanged as this diagnosis socket (1)
replaces the previous one.
Main diagnosis functions

– Fault detection
– Fault analysis
Occurrence
Meaning
Identification
Fault type (static, sporadic, ...)
– Fault saving
– Simulation for troubleshooting
Important note:
The air-conditioning system does not have a CAN connection, as a result any fault messages that are
generated cannot be signalled on the instrumentation. Faults can only be downloaded from the fault
memory of the control unit and displayed using MAN-cats II.
T 69 2 - 37
DEVICE DESCRIPTION
Troubleshooting program
The following troubleshooting program contains all the faults that can be detected by the fault memory.
The sequence of tests corresponds to the numerical succession of fault codes (SPNs), irrespective of the
evaluation of the fault.
During initial testing, always read out the entire fault memory and document all saved faults (MAN-cats
key combination CTRL + F11). This is important because lines and components have to be disconnected
during system troubleshooting, which may cause the corresponding fault messages to be triggered and
saved. Consequently, the fault memory should always be deleted after intermediate inspections. If parts are
exchanged, 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 fault memory, see above.)
Other procedures are only permitted subject to consultation with the Service Department in Munich!
Equally, control units are only allowed to be exchanged under warranty subject to consultation with the Service
Department in Munich.
Repeat the test and delete the fault memory after correcting the fault and checking the repair.
The fault memory should always be deleted using MAN-cats
Always delete the fault message and observe the fault before replacing any component or control unit.
If several faults are entered, always start with the test instructions which do not require components
or control units to be replaced. Make sure the ignition is switched off before commencing repairs
and replacing components or control units. Failure to switch off the ignition will lead to fault memory
entries (SPNs) in the various electronic control units.
Always test the lines in the following order:

– Discontinuity or contact resistance (e.g. receptacles bent open, connectors or receptacles pushed back or
corroded plug and socket connections)
– 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 or defective even if the corrugated hose appears undamaged on the
outside!
Break the connection to the control unit before measuring resistance values.
Refer to the wiring diagrams for the vehicle in question!
Resistance measurement
– Switch the ignition OFF
– Disconnect the plug at which the measurement is to be taken from the control element.
Voltage measurement
– Switch the ignition ON
– The measurement is taken directly on the control element with air-conditioning system.
Voltage is measured with the engine running and the vehicle stationary.
2 - 38 T 69
DEVICE DESCRIPTION
SPN list (fault codes) and fault code description, control element
The following table lists the fault codes that appear on the instrumentation display or the MAN-cats screen in
the event of an fault. The fault causes and responses are documented for the listed fault code descriptions.
SPN – Suspect Parameter Number – Fault location
FMI – Failure Mode Identification – Fault type
Address: 98 air-conditioning system
Version: 1.80
Note: See test step list for test step
SPN SPN-Plain text

Description
00876 PLAIN TEXT: Compressor coupling
TYPE OF FAULT: 7 – General short circuit
CAUSE: High or low-pressure in refrigerant circuit, defective high/low-pressure switch, defective
compressor coupling, fault in cable line, defective control element.
RESPONSE: Cooling system does not operate or operates permanently.
REMEDY: Check cables, check plug connections, check compressor coupling, check control
element (A474), measure voltage.
Test step:
Perform voltage measurement:
Refrigerant tank, compressor solenoid valve; control element – between pin X1/6 (+) and pin
X1/12 (-): 16 - 32V (UBat)
Fit a new control element and/or high/low-pressure switch and/or compressor coupling if no fault
can be found.
00877 PLAIN TEXT: Evaporator temperature sensor
TYPE OF FAULT: 5 – Short circuit to ground
TYPE OF FAULT: 6 – Short circuit to Ubat
CAUSE: Defective evaporator sensor, fault in cable line, defective control element.
RESPONSE: Default value -5°C.
REMEDY: Check cables, check plug connections, check evaporator sensor, check control
element (A474), measure resistance.
Test step:
Perform resistance measurement:
Air-conditioning system evaporator sensor supplied by Behr; control element – between pin X2/4
(+) and pin X2/5 (-): ~= 10 kΩ at 25 °C
Renew control element and/or air-conditioning system evaporator sensor supplied by Behr if no
fault can be found.
03001 PLAIN TEXT: Interior air temperature sensor
CAUSE: Defective air-conditioning system temperature sensor, fault in cable line, defective
control element.
RESPONSE: Default value 22°C.
REMEDY: Check cables, check plug connections, check air-conditioning system temperature
sensor, check control element (A474), measure resistance.
Test step:
Air-conditioning system temperature sensor; control element – between pin X1/4 (+) and pin X1/8
(-): ~= 10kΩ
Renew control element and/or air-conditioning system temperature sensor if no fault can be found.
T 69 2 - 39
DEVICE DESCRIPTION
SPN SPN-Plain text

Description
03002 PLAIN TEXT: External air temperature sensor
CAUSE: Defective air-conditioning system external temperature sensor, fault in cable line,
defective control element.
REMEDY: Check cables, check plug connections, check air-conditioning system external
temperature sensor, check control element (A474), measure resistance.
Test step:
Air-conditioning system external temperature sensor supplied by Behr; control element – between
pin X2/13 (+) and pin X2/5 (-): ~= 10 kΩ at 25 °C
Renew control element and/or air-conditioning system external temperature sensor supplied by
Behr if no fault can be found.
03003 PLAIN TEXT: Blow-out air temperature sensor (heat exchanger sensor)
CAUSE: Defective air-conditioning system heat exchanger sensor, fault in cable line, defective
control element.
REMEDY: Check cables, check plug connections, check air-conditioning system heat exchanger
sensor, check control element (A474), measure resistance.
Test step:
Air-conditioning system heat exchanger sensor supplied by Behr; control element – between pin
X2/10 (+) and pin X2/5 (-): ~= 10 kΩ at 25 °C
Renew control element and/or air-conditioning system heat exchanger sensor supplied by Behr
if no fault can be found.
03004 PLAIN TEXT: Bypass flap motor potentiometer
TYPE OF FAULT: 8 – Defective signal
CAUSE: Faults 5 and 6 Defective motor potentiometer, fault in cable line, defective control
element.
RESPONSE: Faults 5 and 6 Default value central position.
CAUSE: Fault 8 Defective motor potentiometer, bypass flap sticking, fault in cable line, defective
control element.
RESPONSE: Fault 8 Motor cannot be moved, unfavourable temperature distribution.
REMEDY: Check cables, check plug connections, check heater element bypass flap feedback
potentiometer, check control element (A474), measure resistance, measure voltage.
Test steps:
Air-conditioning system heater element bypass flap feedback potentiometer supplied by Behr;
control element – between pin X2/7 (+) and pin X2/5 (-): ~= 95 - 105 kΩ
Reference voltage 5 V – air-conditioning system supplied by Behr; control element – between pin
X2/11 (+) and pin X2/5 (-): ~= 5 V
Renew control element and/or air-conditioning system heater element bypass flap feedback
potentiometer supplied by Behr if no fault can be found.
2 - 40 T 69
DEVICE DESCRIPTION
SPN SPN-Plain text

Description
03005 PLAIN TEXT: Heating valve
CAUSE: Faults 5 and 6 Defective solenoid valve, fault in cable line, defective control element.
RESPONSE: Fault 5 Heater does not operate or operates permanently.
RESPONSE: Fault 6 Permanent heating.
REMEDY: Check cables, check plug connections, check solenoid valve, EP valve,
air-conditioning system at front end (Y117), check control element (A474), measure voltage.
Test step:
Solenoid valve, EP valve, air-conditioning system at front end – engine must be started; control
element – between pin X1/10 (+) and pin X1/3 (-): ~= 0 V solenoid valve closes; 16 - 32 V (Ubat)
solenoid valve opens
Renew control element and/or solenoid valve, EP valve, air-conditioning system at front end if no
fault can be found.
03006 PLAIN TEXT: Recirculating air flap motor
TYPE OF FAULT: 10 – Interruption
CAUSE: Defective recirculation motor, fault in cable line, defective control element.
RESPONSE: Recirculating air flap cannot be moved.
REMEDY: Check cables, check plug connections, check air-conditioning system fresh
air/recirculating air flap motor, fresh air position, check control element (A474), measure voltage.
Test steps:
Air-conditioning system fresh air/recirculating air flap motor, fresh air position supplied by Behr;
control element – between pin X2/6 (+) and pin X2/9 (-): ~= 16 - 32 V (Ubat) operate fresh air
/recirculating air flap switch (S123); ~= 0 V do not operate fresh air/recirculating air flap switch
(S123)
Air-conditioning system fresh air/recirculating air flap motor, fresh air position supplied by Behr;
control element – between pin X2/9 (+) and pin X2/6 (-): ~= 16 - 32 V (Ubat) operate fresh air
/recirculating air flap switch (S123); ~= 0 V do not operate fresh air/recirculating air flap switch
(S123)
Renew control element and/or air-conditioning system fresh air/recirculating air flap motor, fresh
air position supplied by Behr if no fault can be found.
03007 PLAIN TEXT: Bypass flap motor
CAUSE: Defective motor, fault in cable line, defective control element.
RESPONSE: Motor cannot be moved, unfavourable temperature distribution.
REMEDY: Check cables, check plug connections, check heater element bypass flap motor, check
control element (A474), measure voltage.
Test steps:
Open heater element bypass flap motor – air-conditioning system supplied by Behr; control
element – between pin X2/12 (+) and pin X2/15 (-): ~= -16 - 32 V (Ubat) operate REHEAT
pushbutton switch (de-humidify) (S545), REHEAT function activated; brief signal; ~= 16 - 32 V
(Ubat) operate REHEAT pushbutton switch (de-humidify) (S545), REHEAT function deactivated;
brief signal
Close heater element bypass flap motor – air-conditioning system supplied by Behr; control
element – between pin X2/15 (+) and pin X2/12 (-): ~= -16 - 32 V (Ubat) operate REHEAT
pushbutton switch (de-humidify) (S545), REHEAT function activated; brief signal; ~= 16 - 32 V
(Ubat) operate REHEAT pushbutton switch (de-humidify) (S545), REHEAT function deactivated;
brief signal
Renew control element and/or air-conditioning system heater element bypass flap motor supplied
by Behr if no fault can be found.
T 69 2 - 41
DEVICE DESCRIPTION
SPN SPN-Plain text

Description
03008 PLAIN TEXT: Blower control voltage
TYPE OF FAULT: 1 – Signal or value too high
TYPE OF FAULT: 2 – Signal or value too low
CAUSE: Defective blower controller, fault in cable line, defective control element.
RESPONSE: Blower is not controlled correctly.
REMEDY: Check cables, check plug connections, check blower controller, check control element
(A474), measure voltage.
Test steps:
Electrical power supply to blower dial for blower control (S547); control element – between pin
X2/14 (+) and pin X2/3 (-): ~= 0 V “OFF” position; ~= 0 - 10.3 V “AUTO” position; ~= 2 - 8.3 V
linear range; ~= 10 V “MAX” position
Electrical power supply to blower controller terminal 15 – air-conditioning system supplied by
Behr; control element – between pin X2/15 (+) and pin X2/3 (-): ~= 16 - 32 V (Ubat)
Renew control element and/or air-conditioning system blower dial supplied by Behr if no fault can
be found.
2 - 42 T 69
DEVICE DESCRIPTION
Test step list for air-conditioning system

The test step list enables the components and/or functions of the air-conditioning system to be checked with
a multimeter (e.g. FLUKE 77 or 87).
Test description
In the test step list presented in this chapter (example: test step 1), the first test contact is designated “Pin
X1/4” and the second test contact is designated “Pin X1/8”. Use a multimeter to measure the resistance
between these pins. Measure directly on the control element for the cab heating with air-conditioning
system. The measuring mode to be set on the measuring instrument (multimeter) is shown between
test contacts (pins) listed in column 3.
Example: Setting “V” = Voltage measurement
Example: Setting “Ω” = Resistance measurement
Once the test requirements have been fulfilled, the value indicated on the measuring device (actual
characteristic) can be compared with the desired value (desired characteristic).
Two sample measurements are described below:
When measuring voltages, switch on the ignition and leave the plug of the control element connected.
In this example, the electrical power supply to the control element is measured between pin X1/10 – positive
line and pin X1/12 – earth line.
The measured value obtained using the FLUKE 77 multimeter is 22.67V (battery voltage).
When measuring resistance values, switch off the ignition and disconnect the plug at which the resistance
value is to be measured.
T 69 2 - 43
DEVICE DESCRIPTION
In this example, the resistance on the heat exchanger sensor (supplied by Behr) is measured between pin
X2/10 – heat exchanger input signal and pin X2/5 – heat exchanger checkback signal.
The value measured with the FLUKE 77 multimeter is 10.67 kΩ.
Test step list
SN: ............................................................... Tester: ..........................................................

Customer:......................................................... First registered: .............................................
Vehicle model: ................................................ Chassis no.: ............................................
Engine model: ...................................................... Engine number: .............................................
...................................................................... Control unit no.: ...........................................
Mileage: ................................................ Date: .........................................................
Use MAN-cats II to read out the fault memory of the control element for the cab heating with air-conditioning
system (A474). The test step list is designed to pinpoint the entered active faults.
– Use the vehicle-specific overviews and wiring diagrams for troubleshooting.

– Voltage measurements are taken with the ignition switched on, the engine running and the vehicle
stationary.
– When a resistance is being measured, the ignition is switched off.
– Voltages and resistances are measured between the + connection (pin +) and the - connection (pin -) on
the multimeter (e.g. FLUKE 77 or 87).
– Never measure at the plug contacts themselves without using suitable test probes! Danger of
bending open the contacts!
Resistance measurement
– Ignition OFF
– Disconnect the plug at which the measurement is to be taken from the control element.
Interior air temperature sensor
Control element pin Measuring device Measured

Desired value [Ω]
designation Pin+ Pin- value [Ω]
Internal air-conditioning
X1/4 X1/8
temperature sensor (B393) ~= 10kΩ ..................
Line number 23112 31012
Engine start signal

Desired value [Ω]
Engine start signal from central

X1/5 X1/12
computer 2 (A302 pin F2/17) ~= 9 - 16kΩ ..................
2 - 44 T 69
DEVICE DESCRIPTION
Evaporator sensor

Desired value [Ω]
evaporator sensor supplied X2/4 X2/5
by Behr (A480) ~= 10 kΩ at 25 °C ..................
Yellow Red
Line colour
/green /white
Checkback potentiometer heater element bypass flap

Desired value [Ω]
checkback potentiometer
X2/7 X2/5
heater element bypass flap
supplied by Behr (A480) ~= 95 - 105 kΩ ..................
White Red
Line colour
/red /white
Heat exchanger sensor

Desired value [Ω]
Air-conditioning system heat

exchanger sensor supplied X2/10 X2/5
by Behr (A480) ~= 10 kΩ at 25 °C ..................
Red
Line colour Black
/white

Desired value [Ω]
external temperature sensor X2/13 X2/5
supplied by Behr (A480) ~= 10 kΩ at 25 °C ..................
White Red
Line colour
/yellow /white
T 69 2 - 45
DEVICE DESCRIPTION
Voltage measurement
– Ignition ON
– The measurement is taken directly on the control element with air-conditioning system.
Voltage is measured with the engine running and the vehicle stationary. The operating voltage is
approximately 28 V, the operating voltage range is 16 - 32 V.
Voltage supply

Desired value [V]
designation Pin+ Pin- value [V]
Electrical power supply to

control element – terminal
X1/10 X1/12
15 front-end heater fuse, 16 - 32V (UBat) ..................
air-conditioning system (F397)
Electrical power supply
terminal 58 parking lights 16 - 32 V (Ubat) when
Fuse, instrument, switch and X1/1 X1/12 parking lights “ON”;
pushbutton unit illumination ..................
operate light switch
(F125) (S111)
Electrical power supply to
blower controller terminal 15
X2/1 X2/3
Air-conditioning system 16 - 32V (UBat) ..................
supplied by Behr (A480)
Line colour Red Brown
to blower control dial
X2/14 X2/3
(S547) in ~= 0 V ..................
– “OFF” position
Line colour Violet Brown
X2/14 X2/3
(S547) in ~= 0 - 10.3 V ..................
– “AUTO” position
X2/14 X2/3
(S547) in ~= 2 - 8.3 V ..................
– linear range
X2/14 X2/3
(S547) in ~= 10 V ..................
– “MAX” position
terminal 58 dimmed X1/7 X1/12
– when terminal 58 “OFF” 0V ..................
2 - 46 T 69
DEVICE DESCRIPTION

Desired value [V]

terminal 58 dimmed X1/7 X1/12
– when terminal 58 “ON” ~= 12 V ..................
Solenoid valve air-conditioning system at front end

Desired value [V]
Solenoid valve, EP valve,

air-conditioning system at front
end (Y117) X1/10 X1/3
Engine must be started ~= 0 V ..................
– Solenoid valve closes
Solenoid valve, EP valve,
air-conditioning system at front
end (Y117) X1/10 X1/3
Engine must be started 16 - 32V (UBat) ..................
– Solenoid valve opens
Engine start signal

Desired value [V]

computer 2 (A302 pin F2/17) X1/5 X1/12
– Engine not running ~= 0 V ..................

computer 2 (A302 pin F2/17) X1/5 X1/12
– Engine running 16 - 32V (UBat) ..................
Refrigerant tank, compressor solenoid valve

Desired value [V]
Refrigerant tank, compressor

solenoid valve on refrigerant
tank with high/low-pressure
X1/6 X1/12
switch (B203), magnetic
coupling on compressor 16 - 32V (UBat) ..................
(Y114)
23101 /
Line number 31000
23300
Note: The evaporator temperature only changes if the engine is running.
T 69 2 - 47
DEVICE DESCRIPTION
Fresh air/recirculating air flap motor

Desired value [V]
Fresh air/recirculating air flap

motor in fresh air position
supplied by Behr (A480) X2/6 X2/9
– Operate fresh air ~= 16 - 32 V (Ubat) ..................
/recirculating air flap switch
(S123)
Line colour Yellow Grey
Fresh air/recirculating air flap
motor in fresh air position
supplied by Behr (A480) X2/6 X2/9
– Do not operate fresh air ~= 0 V ..................
(S123)
Line colour Yellow Grey
Fresh air/recirculating air
flap motor in recirculating air
position
X2/9 X2/6
supplied by Behr (A480) ~= 16 - 32 V (Ubat) ..................
– Operate fresh air
(S123)
Line colour Grey Yellow
Fresh air/recirculating air
flap motor in recirculating air
position
X2/9 X2/6
supplied by Behr (A480) ~= 0 V ..................
– Do not operate fresh air
(S123)
Line colour Grey Yellow
motor – open
supplied by Behr (A480) X2/12 X2/15 ~= 16 - 32 V (Ubat)
– Operate “REHEAT” REHEAT function
..................
pushbutton switch activated; brief
(de-humidify) (S545) signal
Yellow Grey
Line colour
/black /red
2 - 48 T 69
DEVICE DESCRIPTION

Desired value [V]

motor – open
supplied by Behr (A480) X2/12 X2/15 ~= -16 - 32 V (Ubat)
..................
pushbutton switch deactivated; brief
Yellow Grey
Line colour
/black /red
motor – close
supplied by Behr (A480) X2/15 X2/12 ~= -16 - 32 V (Ubat)
..................
pushbutton switch activated; brief
Yellow
Line colour Grey/red
/black
motor – close
supplied by Behr (A480) X2/15 X2/12 ~= 16 - 32 V (Ubat)
..................
pushbutton switch deactivated; brief
Yellow
Line colour Grey/red
/black
Reference voltage

Desired value [V]
Reference voltage 5 V
Air-conditioning system X2/11 X2/5
supplied by Behr (A480) ~= 5 V ..................
Black Red
Line colour
/white /white
Diagnosis, K-line

Desired value [V]
Diagnosis K-line diagnostic

socket (X200) 16 - 32 V (Ubat - 2 V)
X1/9 X1/12
Condition: No data traffic on (MAN-cats II not ..................
K-line connected)
Diagnosis K-line diagnostic
socket (X200) X1/9 X1/12 0 - 32 V (Ubat - 2 V)
With data traffic on K-line (MAN-cats II ..................
connected)
T 69 2 - 49
DEVICE DESCRIPTION
Deleting the fault memory
No more active faults are allowed to be stored in the fault memory once all tests have been performed
and no faults are found!
Before deleting the fault memory, download it using MAN-cats II and if it contains any non-diagnosed faults
then these must be archived. Then delete the fault 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.
2 - 50 T 69
ADDITIONAL WIRING DIAGRAMS

OVERVIEWS
T 69 3 - 51
BRIEF OVERVIEW OF THE AIR-CONDITIONING SYSTEM
04.01
Legend
A100 Central electrical system
A302 Central computer 2
A474 Controls, cab heating without / with air-conditioning system
A480 Air-conditioning system supplied by BEHR
B203 High/low-pressure switch, refrigerant tank (air-conditioning system)
B393 Temperature sensor, interior air (air-conditioning system)
F397 Fuse, heater blower/air-conditioning system
F125 Fuse, pushbutton unit illumination
K718 Relay, temperature sensor, interior air, air-conditioning system
R106 Potentiometer, instrument lighting
S123 Switch, fresh air/recirculating air flap
S544 Switch, AC ON
S545 Switch, REHEAT
S546 Rotary switch, interior temperature
S547 Rotary switch, blower
X200 Diagnosis socket (MAN-cats)
X1560 Relay socket K718, K...
X1754 Crimped connector, line 59104
X1822 Plug connection, air-conditioning system
X1823 Plug connection, air-conditioning system, terminal 15
X2541 Potential distributor, 21-pin, line 31000
X2544 Potential distributor, 21-pin, K-line
Y114 Magnetic clutch, compressor
Y117 Solenoid valve, front air-conditioning system
——– ——————————————————————————-
1 Evaporator sensor
2 External temperature sensor
3 Heat exchanger sensor
4 Heater element bypass flap
5 Fresh air/recirculating air
6 Sequence controller
7 Blower
T 69 3 - 52
BRIEF OVERVIEW OF THE AIR-CONDITIONING SYSTEM
T 69 3 - 53
WIRING DIAGRAM NO. 81.99192.1380
Air-conditioning system wiring diagram sheet 1 of 2

04.01
Legend
A Voltage supply, water timing valve, internal air temperature sensor
——– ————————————————————————————————–
B393 Temperature sensor, interior air (air-conditioning system)
F397 Fuse, heater blower/air-conditioning system
K718 Relay, temperature sensor, interior air, air-conditioning system
S123 Switch, fresh air/recirculating air flap
S544 Switch, AC ON
S545 Switch, REHEAT
S546 Rotary switch, interior temperature
S547 Rotary switch, blower
X1560 Relay socket K718, K...
X2541 Potential distributor, 21-pin, line 31000
Y117 Solenoid valve, front air-conditioning system
T 69 3 - 54
T 69 3 - 55
WIRING DIAGRAM NO. 81.99192.1380

04.01
Legend
A Refrigerant tank
B Magnetic coupling, compressor
C Air-conditioning system supplied by BEHR
——– ——————————————————————————-
A480 Air-conditioning system supplied by BEHR
B203 High/low-pressure switch, refrigerant tank (air-conditioning system)
X1551 Plug connection, engine/EDC/gearbox II
X2544 Potential distributor, 21-pin, K-line
Y114 Magnetic clutch, compressor
——– ——————————————————————————-
1 Sequence controller
2 Blower
3 Fresh air/recirculating air
4 Heater element bypass flap
5 Heat exchanger sensor
6 External temperature sensor
7 Evaporator sensor
T 69 3 - 56
T 69 3 - 57

AC System MAN TGA, TGM

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AC System MAN TGA, TGM

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Electrical System

Copy deadline: 03.2005

Best wishes from

MAN Nutzfahrzeuge Aktiengesellschaft

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

2005 MAN Nutzfahrzeuge Aktiengesellschaft

Redaktion: VSAID-Steyr, HA, 03.2005

Safety instructions .................................................................................................... 1 - 1

System description .................................................................................................. 2 - 11

Additional wiring diagrams

Refrigerant oil fill volume ..........................................................................................................................2 - 22

FDR Dynamic handling control

PWM Pulse Width Modulation (also see PBM)

WLE Swap-body unit

1. Regulations for preventing accidents leading to injury to personnel

– Secure units during their removal.

Working on the brake system

Operating the engine

Working on high-pressure lines

Working on the vehicle electrical system

Caution! Battery acid is poisonous and corrosive!

Working on plastic tubes - Danger of damage and fire!

Working with the cab tilted

Working on the air-conditioning system

2. Notes on preventing damage and premature wear on units

3. Limited liability for accessories and parts

Attachments and special bodies

Taking out of operation and storing

4. Handling brake pads and similar components

5. Regulations for avoiding injury and environmental contamination

Cleaning the cooling circuit

Cleaning the filter insert

Used engine/gear oil

6. Health protection precautions

- Oils can damage groundwater quality -

Extract from "Information on dealing with used engine oil"

Trucknology Generation A (H01-H99)

Model Model designation Model Model designation

Model Model designation Model Model designation

Trucknology Generation L (N01-N99)

Model Model designation Model Model designation

Trucknology Generation M (N01-N99)

Model Model designation Model Model designation

EXPLANATORY NOTES TO THE WIRING DIAGRAMS

1 Electrical component designation 7 Plug connection (example: 1-pin plug

Installation positions for location identifiers

Installation positions for left-hand drive vehicles (TGL/TGM/TGA)

A Rear of vehicle H2 A-pillar, driver's side

Installation positions for right-hand drive vehicles (TGL/TGM/TGA)

A Rear of vehicle J2 A-pillar, driver's side

Refrigerant circuit and its components

The required volume of refrigerant is controlled by the expansion valve.

Function diagram of the refrigerant circuit

1 Evaporator 10 Solenoid valve, air-conditioning system at

Description of the refrigerant circuit

Control element, cab heating with air-conditioning system (A474)

Connector pin assignment

Pin Line no. Circuit Designation

Pin Line no. Circuit Designation

Pin Line no. Circuit Designation

External temperature sensor

Heat exchanger sensor (blow-out air temperature sensor)

Internal air-conditioning temperature sensor (B393)

Connector pin assignment

Pin Line no. Designation

Selecting between air-conditioning system modes AC or REHEAT