Electrical System
Central Electrical System

Trucknology Generation A (TG-A)

1999 | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 10 11 | 12

Publication no.: System Description

81.99198-5402 T 80

MAN Nutzfahrzeuge Aktiengesellschaft Elektrische Anlage TG-A

Dachauer Str. 667 oder Postfach 50 06 20 Systembeschreibung T 80
80995 MÜNCHEN 80976 MÜNCHEN - englisch -
Printed in Germany
Electrical System

Central Electrical System

System Description T 80

Trucknology Generation A (TG-A)

81.99198-5402
ELECTRICAL SYSTEM

Please contact your MAN service centre to check whether the desired modification/conversion
requires ex works confirmation/approval/release. Fax requests for confirmation/approval/
release to the relevant department.
Modifications subject to approval: Department TDB, Fax: ++49 (0)89 1580 4264.
Other: ... VSTT ...
Attach a copy of the vehicle documents to the fax or indicate the vehicle identification number
(FIN [VIN] = WMA ...) and vehicle number (7-digit number).

Modifications which necessitate reprogramming will be defined (in good time). Until such time,
all modifications must be carried out by trained personnel (MAN-cats II training: NFG
electronics specialists) in consultation with the Munich plant (VSTT, TDB).

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

 1999 MAN Nutzfahrzeuge Aktiengesellschaft

Reprinting, copying or translation is not allowed without written permission from MAN
All rights under the copyright law are strictly reserved by MAN

VSWY / HA 10.1999 Übersetzung + Satz: emes GmbH

Friedrichshafen

0.01 - 2 T 80
 ELECTRICAL SYSTEM

Table of contents

Electrical System .......................................................................................................................... 0

Table of contents.......................................................................................................................... 0.11 - 1
Index............................................................................................................................................. 0.12 - 1
Abbreviations................................................................................................................................ 0.13 - 1

General information...................................................................................................................... 1
Safety instructions ........................................................................................................................ 1.20 - 1

Description of components ......................................................................................................... 4

Central electrical system - installation position............................................................................. 4.01 - 1
Central electrical system - front view............................................................................................ 4.01 - 2
Central electrical system - rear view ............................................................................................ 4.01 - 4
Connector pin assignment............................................................................................................ 4.01 - 5
Central electrical system - internal wiring ..................................................................................... 4.01 - 9

Diagnosis....................................................................................................................................... 8
System structure, K-lines ............................................................................................................. 8.15 - 1

T 80 0.11 -1
 ELECTRICAL SYSTEM

Index

Abbreviations................................................................................................................................ 0.13 - 1
Table of contents.......................................................................................................................... 0.11 - 1
Safety instructions ........................................................................................................................ 1.20 - 1
Connector pin assignment............................................................................................................ 4.01 - 5
Index............................................................................................................................................. 0.12 - 1
System structure - K-lines ............................................................................................................ 8.15 - 1
Central electrical system - installation position............................................................................. 4.01 - 1
Central electrical system - internal wiring ..................................................................................... 4.01 - 9
Central electrical system - rear view ............................................................................................ 4.01 - 4
Central electrical system - front view............................................................................................ 4.01 - 2

T 80 0.12 - 1
 ELECTRICAL SYSTEM

Abbreviations As of: 10.99

a Acceleration
ABS Anti-lock brake system
ABV Anti-skid system
ACC Adaptive cruise control
ADR International agreement for the transport of dangerous goods
AGB Automatic road speed limiter
AGND Analog ground
AGR Exhaust gas recirculation (EGR)
AHV Trailer brake valve
ALB Automatic load-dependent brake
AMA Antenna mast
ANH Trailer/semitrailer
AS Automatic transmission
ASM Trailer control module
ASR Anti-spin regulator
ASV Trailer control valve
ATC Automatic temperature control
ATF Automatic transmission fluid
AV Exhaust valve

BA Operator's manual
BAM Broadcast announce message
BBA Service brake system
BBV Service brake valve
BKR Brake force regulator
BV Back-up valve
BVA Brake wear indicator
BVS Brake wear sensor
BVV Brake wear sensor supply
BW German Army
BWG Brake value sensor
BZ Brake cylinder

CAN Controller area network (databus system with serial bit transmission)
CAN-H CAN-high data line
CAN-L CAN-low data line
CATS Computer-assisted testing (and diagnostic) system
CBH CAN-brake high
CBL CAN-brake low
CKD Completely knocked down
CNG Compressed natural gas
CPU Central processing unit
CRT Continuously regenerating trap (exhaust silencer, 2-way cat. converter, diesel particulate filter)

DA Destination address
DBR Sustained-action brake relay
DF Speed sensor
DFÜ Data transfer
DIA Diagnosis and information display
DIAK Diagnosis, K-line (data line)
DIAL Diagnosis, L-line (stimulation line)
DIAR Diagnosis, further stimulation
DIN German industrial standard
DKE Throttle valve increase (ASR control)
DKR Throttle valve reduction (ASR control)
DKV Throttle valve specification (ASR control)
DLB Compressed air brake system
DLC Data length code
DM1 Diagnostic message 1

T 80 0.13 - 1
ELECTRICAL SYSTEM

Abbreviations

DPF Diesel particulate filter

DRM Pressure control module (PCM)
DS Pressure sensor
DSV Pressure control valve
DTC Diagnostic trouble code
DV Throttle valve
DZM Rev counter

EBS Electronic brake system

ECAM Electronically controlled air management
ECAS Electronically controlled air suspension
ECU Electronic control unit
EDC Electronic diesel control
EEPROM Electrically erasable programmable read-only memory
EFR Electronic shock absorber control (ESAC)
EHAB Electrohydraulic shut-off device
ELAB Electrical shut-off device
ELF Electronic air suspension
EMS Electronic throttle control (ETC)
EMV Electromagnetic compatibility (EMC)
EOL End-of-line (programming)
EP Injection pump
ER Engine retarder (engine brake)
EV Intake valve

FBA Parking brake system

FFL Freeze frame length
FFR Vehicle management computer
FGB Road speed limiting system (RSL)
FGR Road speed governing system (RSG)
FM Vehicle management
FMI Failure mode identification
FMR Vehicle-engine regulation
FS Tachograph

GDK Controlled diesel catalytic converter

GET Gearbox
GGVS Regulations for the transport of dangerous goods
GS Gearbox control unit
GND Ground (earth)
GP Range-change (planetary group)
GV Splitter

HA Rear axle
HBA Auxiliary brake system
HGB Maximum speed limiter
HST Main switch panel
HTS High sequence protection
Hz Hertz (number of cycles per second)

IBIS Integrated on-board information system

IC Integrated circuit
INA Information display
IMR Integrated mechanical relay module (starter control)
IR Individual regulation
IRM Individual regulation, modified
ISO International Standard Organisation

0.13 - 2 T 80
 ELECTRICAL SYSTEM

Abbreviations

KBZ Combination brake cylinder

KP Kingpin
KSM Customer-specified module
KSW Customer's special request
KWP Key word protocol (protocol for MAN-cats diagnosis)

LBH Air reservoir/tank

LCD Liquid crystal display
LDA Manifold-pressure compensator, aneroid device
LDF Charge air pressure sensor
LDS Air suspension/shock absorber system
LED Light emitting diode
LF Air suspension
LNG Liquefied natural gas
LPG Liquefied petroleum gas
LWR Headlight beam regulator

M-TCO Modular EU tachograph

MAN-cats MAN computer assisted testing (and diagnostic) system
ML Midline
MMI Man-machine interface
MP Motor power box (cable duct on engine block)
MR Engine governor - ASR
MV Solenoid valve
MZ Diaphragm cylinder

n Speed (rpm)
NA Power take-off (PTO)
NBF Needle movement sensor
NFG New vehicle generation
NFZ Commercial vehicle
NLA Trailing axle
NMG New engine generation

OC Occurrence count (errors/faults)

p Pressure
PBM Pulse width modulated signal (PWM)
PCU Pressure control unit
PDU Protocol data unit
Pm Pressure at brake line coupling head
Pme Pressure at tractor-trailer electrical connection
PTO Power take-off
PWM Pulse width modulation

RA Repair manual
RAM Random access memory
RDS Radio data system
RET Retarder
RKL Priority vehicle light
RLV Relay valve
ROM Read only memory

SA Source address
SAE Society of Automotive Engineers
SAMT Semi automatic mechanical transmission

T 80 0.13 - 3
ELECTRICAL SYSTEM

Abbreviations

SD Silencer
sec Second
SG Control unit
SH Select-high control
SKD Semi knocked down
SL Select-low control
SPN Suspect parameter number (fault location number)
SSM Select-smart control
STCO System tachograph

t Time
TC Traction control
TCM Trailer control module
TKU Technical customer document
TMC Traffic message channel
TRS Technical directive, on-road

UBAT Battery voltage

v Velocity (road speed)

VA Front axle
VG Transfer case
VLA Leading axle

WA Maintenance manual
WLE Swap-body unit
WR Warning relay
WS Travel sensor
WSK Torque converter and clutch system

z Retardation/braking factor
ZBR Central on-board computer
ZBRO Central on-board bus computer
ZDR Intermediate speed governing (ISG)
ZE Central electrical system (CES)

λ Slip
µ Coefficient of friction
µC Microcontroller

0.13 - 4 T 80
 GENERAL INFORMATION

Safety instructions

This survey presents a summary of the important regulations listed according to major topics. The intention
is to provide the knowledge needed to avoid accidents which could lead to injury, damage and
environmental pollution.
Additional information is given in the operator’s manual for the vehicle.

Important:
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident
involves skin contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze
spraying into eyes, etc.

Regulations for preventing accidents leading to injury to personnel.

Only authorised technical personnel are entitled to perform inspection, adjustment and repair work.

• Secure the vehicle to prevent it from rolling away.

• Support the frame when working on the pneumatic or spring suspension system.
• Secure units during their removal.

• Only authorised personnel are permitted to start and operate an engine.

• Do not approach moving parts of a running engine too closely.
Do not wear baggy clothing.

• Do not touch an engine with your bare hands when it is at operating temperature:
Danger of burns!

• Keep the area around the engine, ladders and steps free of oil and grease.
Accidents caused by slipping can have very serious consequences.
• Only use tools that are in perfect condition. Damaged or widened spanners can
slip: Risk of injury!
No-one is allowed to stand under an engine suspended from a crane hook.
– Keep all lifting tackle in good condition. –

• Collect any brake fluid that leaks out. Treat brake fluid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.
• Brake fluid is poisonous! Do not allow it to come into contact with food or open
wounds.

• Do not open the coolant circuit until the engine has cooled down. Refer to the
“Maintenance and care jobs” section in the Operator’s Manual if you absolutely
have to open the circuit when the engine is warm.
• Do not attempt to tighten, loosen or open pipelines and hoses (e.g. in lubrication
circuit, coolant circuit or any subsequent hydraulic oil circuit) whilst they are
pressurised. Fluid spraying out represents an injury hazard!
• Do not hold your hands under the jet of fuel when checking the injector nozzles.
•
Do not inhale fuel vapours.

T 80 1.20 - 1
GENERAL INFORMATION

• Always disconnect the batteries before working on the electrical system.

Important! Oxyhydrogen gas may form in enclosed battery boxes. When the
batteries are disconnected this gas may be ignited by sparks produced by other
continuously operating consumers, the tachograph etc. that cannot be shut down.
Blow compressed air through the battery box before disconnecting the batteries!
• Only tow-start the vehicle if the batteries are connected (minimum charge 40%)!
Do not use a boost-charger to jump-start the vehicle! Always disconnect the
positive and negative leads before boost-charging batteries!
• Disconnect the batteries or recharge them every 4 weeks if the vehicle is not in
use.
Caution! Battery acid is poisonous and corrosive. Battery gases are explosive.
• Follow the manufacturer’s instructions when handling batteries.
• Measure voltage only using a suitable measurement device!
The input resistance of the measurement device must be at least 10 MΩ.
• The ignition must be switched off before the wiring harness plugs of the
electronic control units are disconnected or connected up!
When performing electric welding work, connect up the “ANTIZAP SERVICE
MONITOR” protective device (MAN item number 80.78010.0001) in accordance with
the instructions provided with the device.
If this device is not available, disconnect the batteries and join the positive cable to
the negative cable in order to make a conductive connection.
Always earth the welding equipment as close as possible to the welding area. Do not
lay the welding equipment cables parallel to electrical cables in the vehicle.
Refer to the “Guidelines for Welders” for further safety precautions.
The chassis is not intended for use as an earth return.
• If attachments are to be fitted to the vehicle (e.g. a tailgate lift), additional earth
(ground) lines with an adequate cross-section must be fitted as well. Otherwise
the earth connection may be created along wire cables, wiring harnesses,
gearbox shafts, gears etc. and severe damage could result.

• If paint spraying is to be carried out, do not expose the electronic components

to high temperatures (max. 95 °C) for more than brief periods; a time of up to
2 hours is permissible at a maximum of 85 °C. Disconnect the batteries.

Plastic tubes
Important! – Danger of damage and fire!
• The warning sign opposite is attached to the co-driver door beneath the door
lock. It warns you against welding or drilling near to plastic tubes.

1.20 - 2 T 80
 GENERAL INFORMATION

Working on parts containing asbestos

• Certain vehicle components may contain asbestos.

Spare parts and, if necessary, their packaging, are marked
accordingly - see the illustration.

• Asbestos dust may be released when parts containing

asbestos are machined.
Please take the necessary precautionary measures and
observe the following safety advice to avoid possible damage
to your health:

• If possible, carry out the work in question in the open or in an

area equipped with an efficient ventilation system!

• If possible, use hand-operated or slow-running tools equipped

with a dust-collector if required!
Fast-running tools should always be fitted with such a device.

• If possible, wet the workpiece prior to cutting or drilling!

• Spray the dust with water, seal it in a container with a tight-

fitting lid and dispose of it as hazardous waste in an
environmentally sound manner!

Limited liability for accessories and parts

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

Attachments and special bodies

You must comply with the safety instructions and regulations issued by the body maker in question if
attachments or special bodies are fitted.

Taking out of operation or putting into storage

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

T 80 1.20 - 3
 DESCRIPTION OF COMPONENTS

Central electrical system (equipment no. A100)

Installation position

A100

The central electrical system is located on the right inside the vehicle (left-hand drive vehicles). It is behind
a cover in the centre console.
The fuse and relay arrangement is depicted on the adhesive label on the inside of the cover.

T 80 4.01 - 1
DESCRIPTION OF COMPONENTS

Central electrical system - front view

4.01 - 2 T 80
 DESCRIPTION OF COMPONENTS

Key

No. Component Designation

1 F118 Fuse, parking-tail light, right
2 F117 Fuse, parking-tail light, left
3 F125 Fuse, instrument, switch and location lighting
4 F375 Fuse, cab, outside (terminal 15)
5 F372 Power supply, vehicle management computer (terminal 15)
6 F164 Fuse, ECAS (terminal 15)
7 F243 Fuse, central on-board computer, continuous positive
8 Not used
9 F412 Fuse, tachograph, instrumentation (terminal 30)
10 F152 Fuse, retarder (terminal 15)
11 F399 Fuse, alternator (terminal 15)
12 F236 Fuse, EDC (terminal 15)
13 F398 Fuse, tachograph, instrumentation (terminal 15)
14 F128 Fuse, continuously operating consumers
15 F244 Fuse, central on-board computer (terminal 30-1)
16 F245 Fuse, central on-board computer (terminal 30-2)
17 F371 Power supply, vehicle management computer (terminal 30)
18 F376 Fuse, cab, inside (terminal 15)
19 F246 Fuse, central on-board computer (terminal 15)
20 F314 Fuse, reversing light
21 F112 Fuse, windscreen washers and wipers
22 F374 Fuse, Intarder/retarder (terminal 30)
23 F106 Fuse, flame start system
24 F161 Fuse, EBS/ABS, power supply, pressure control valve
25 F160 Fuse, EBS/ABS, power supply, trailer
26 F162 Fuse, EBS/ABS, control
27 F366 Fuse, ECAM/ECAS (terminal 15)
28 F397 Fuse, front end heater/air-conditioning system
29 Spare fuse
30 Spare fuse
31 Spare fuse
32 Spare fuse
33 Spare fuse
34 Spare fuse
35 Spare fuse
36 Spare fuse
37 Jumper
38 Fuse puller
39 K116 Relay, parking-tail light
40 K106 Relay, wiper interval
41 K102 Relay, flame start system
42 K171 Relay, consumers (terminal 15)

ZE = Connector, central electrical system (CES)

(refer to central electrical system internal wiring)

T 80 4.01 - 3
DESCRIPTION OF COMPONENTS

Central electrical system - rear view

4.01 - 4 T 80
 DESCRIPTION OF COMPONENTS

Connector pin assignment

Connector A1

Pin Line no. Designation

1 30006 Terminal 30
2 30006 Terminal 30, interior light/hazard warning lights/light switch
3 25009 Operator panel, vehicle heating/air-conditioning (terminal 15)
4 60027 Terminal 30, vehicle management computer
5 20501 Windscreen wiper motor M 102 (terminal 31b)
6 --- Not used
7 30006 Terminal 30, door lock (driver side) A465
8 30006 Terminal 30, door lock (co-driver side) A466
9 15002 Terminal 15
10 58000 Terminal 58
11 43002 Terminal 30, Intarder/retarder
12 --- Not used
13 93005 Terminal 15, ECAM/ECAS
14 15002 Terminal 15, central on-board computer
15 15002 Jumper to A2/14
16 58000 Terminal 58
17 58000 Terminal 58
18 16006 Terminal 15, instrumentation/tachograph

Connector A2

Pin Line no.

1 20000 Terminal 15, windscreen wiper motor M102 (53a)
2 20000 Terminal 15, steering column switch S108 (53c)
3 73001 Terminal 30, EBS
4 70002 Terminal 30, ECAS
5 30000 Terminal 30, door modules (F382/F383)
6 30000 Terminal 30
7 15014 Terminal 15, accelerator pedal unit A410
8 73002 Terminal 30, EBS A402
9 15021 Terminal 15, alternator G102
10 43004 Terminal 15, Intarder/retarder
11 30009 Terminal 30, instrumentation/tachograph
12 73000 Terminal 30, EBS A402
13 15001 Terminal 15
14 15002 Terminal 15
15 15001 Terminal 15
16 15001 Terminal 15
17 30000 Terminal 30
18 --- Not used

T 80 4.01 - 5
DESCRIPTION OF COMPONENTS

Connector A3

Pin Line no. Designation

1 58303 Outline light, front left E115
2 60028 Terminal 15, vehicle management computer A403
3 20502 Steering column switch S108 (turn indicators, wipers, headlights)
4 58302 Outline light, front right E114
5 50300 Terminal 50
6 --- Not used
7 --- Not used
8 --- Not used

Connector B

Pin Line no. Designation

1 30000 Terminal 30
2 15006 Terminal 15
3 30000 Terminal 30
4 --- Not used
5 58303 Tail light, left A189
6 58316 Connection, trailer socket 1
7 58302 Tail light, right A190
8 58317 Connection, trailer socket 1

Connector C

Pin Line no. Designation

1 --- Not used
2 --- Not used
3 43001 Terminal 15, reversing light
4 --- Not used
5 --- Not used
6 17301 Flame glow plug
7 --- Not used
8 --- Not used

Connector D

Pin Line no. Designation

1 58303 Parking light, left, front
2 --- Not used
3 15006 Terminal 15, steering column switch, horn
4 58302 Parking light, right, front
5 71505 Relay, reversing light K250
6 --- Not used

4.01 - 6 T 80
 DESCRIPTION OF COMPONENTS

Connector F

Pin Line no. Designation

1 16000 Terminal 15
2 --- Not used
3 16000 Terminal 15, button, light switch, illumination learning, rear fog
lamp, diagnosis X200
4 16000 Terminal 15, differential lock
5 16000 Terminal 15, auxiliary heater
6 16000 Terminal 15, door module

Connector G

Pin Line no. Designation

1 31000 Ground, windscreen wiper motor
2 31000 Ground, heater blower
3 31000 Ground, headlight beam regulator
4 31000 Ground, turn indicators, left
5 31000 Ground, cigarette lighter
6 31000 Ground to connector H

Connector H

Pin Line no. Designation

1 31000 Ground to connector G
2 31000 Ground, door module, driver side
3 31000 Ground, door module, co-driver side
4 31000 Ground, door module
5 31000 Ground, entry lighting
6 31000 Ground, windscreen washer pump

Connector I

Pin Line no. Designation

1 --- Not used (parking light, right for bodymaker)
2 --- Not used (parking light, left for bodymaker)

Pin 90/1

Connected with 90/2 via jumper X1364

Terminal 30, steering lock

Terminal 30, working spotlight
Terminal 30, cargo space lighting
Terminal 30, refrigerator compartment
Terminal 30, sliding roof
Terminal 30, cab tilt mechanism, electric
Terminal 30, auxiliary heater

T 80 4.01 - 7
DESCRIPTION OF COMPONENTS

Pin 90/2

Connected with 90/1 via jumper X1364 and with 91 via jumper X1365

Terminal 30 from engine

Terminal 30 for 12 V - socket
Terminal 30 for 24 V - socket
Terminal 30 for sunblind, electric

Pin 91

Connected with 90/2 via jumper X1365

Terminal 30, cigarette lighter

Terminal 30, windscreen heater
Terminal 30, AS-Tronic

Pin 92

Ground from engine

Ground to earthing point, cab

Pin 94

Terminal 15, jumper to fuse F152 (number 10) and F399 (number 11)
Terminal 15, AS-Tronic
Terminal 15, seat heating/seat adjustment
Terminal 15, set-up, following/trailing control-semitrailer
Terminal 15, tailgate

Pin 95

Central on-board computer-ground from engine

Central on-board computer-ground, various consumers (X1830)
Central on-board computer-ground to central on-board computer
Central on-board computer-ground to central on-board computer

Pin 96

Not yet used

4.01 - 8 T 80
 DESCRIPTION OF COMPONENTS

Central electrical system - internal wiring

Key

ZE = Connector, central electrical system/central on-board computer (CES)

1 Parking light, tractor, right 11 Connected with CES 12

2 Parking light, trailer, left 12 Connected with CES 11
3 Parking light, trailer, right 13 Terminal 30 via battery master switch
4 Relay, parking lights 14 Power supply, parking light, left
5 Starter, terminal 50 15 Connected with CES 16
6 Relay, wiper interval 16 Connected with CES 15
7 Parking light, tractor, left 17 Terminal 15
8 Relay, flame start 18 Terminal 30, not switched
9 Terminal 30 via battery master switch 19 Flame start, input
10 Power supply, parking light, right 20 Flame start, output

T 80 4.01 - 9
 DIAGNOSIS

System structure, K-lines

All the control units testable using the MAN-cats diagnostic system are connected with diagnosis socket
X200 pin ... via a K-line. The diagnostic system stimulates a certain control unit via the K-line. The control
unit replies and digitally transfers the faults stored in the fault memory via the K-line.

X200

TM / TM1
FFR
ACC
ZBR II
KSM
DPF/GDK
RET
EDC

GET

HZG
ECAM
KLIMA
EBS
AIRBAG
ECAS/
EFR
FSS

ACC Adaptive cruise control GET Gearbox control unit

AIRBAG Airbag control unit HZG Heating control
DPF/GDK Diesel particulate filter/ KLIMA Air-conditioning system
controlled diesel catalytic converter KSM Customer-specified module
EBS Electronic brake system RET Retarder/Intarder control
ECAM Electronically controlled air management TM Door module, driver side
ECAS/EFR Electronic air suspension TM1 Door module, co-driver side
EDC Electronic diesel control ZBR II Central on-board computer
FFR Vehicle management computer X200 Diagnosis socket
FSS Driver seat control unit

T 80 8.15 - 1