MAN TGA K 90 Wiring Diagram

4.6 (7)

Electrical system

Trucknology Generation A (TG-A)

2002	1 \| 2	3	4 \| 5 \| 6 \| 7 \| 8 \| 9 \| 10 \| 11 \| 12

Publication no.:

81.99198-5972

Wiring diagrams

2nd Edition K 90

MAN Nutzfahrzeuge Aktiengesellschaft		Elektrische Anlage TG-A
Dachauer Str. 667	oder Postfach 50 06 20	Schaltpläne K 90 (2. Ausgabe)
80995 MÜNCHEN	80976 MÜNCHEN	– englisch –
		Printed in Germany

Electrical system

Wiring diagrams K 90 (2nd edition)

Trucknology Generation A (TG-A)

81.99198-5972

ELECTRICAL SYSTEM

Subject to technical changes in the course of continuing development.

1999 MAN Nutzfahrzeuge Aktiengesellschaft

Reprinting, duplication or translation are not permitted without written consent from MAN. MAN Nutzfahrzeuge AG specifically reserves all rights conferred by law concerning copyright.

VSWY / OB/AM 03.2002	Satz: emes GmbH
	Friedrichshafen
0.01 - 2	K 90

ELECTRICAL SYSTEM

Preface

All series and additional wiring diagrams are documented in the instructions for the “wiring diagrams” .

The series wiring diagrams (Ch. 3.00) and the additional wiring diagrams (Ch. 4.00) are shown in detail to include legends and the names of the circuits.

The present manual is based on wiring diagrams that have been created with the help of a graphics program (CAD).

This allows the instructions to be updated at short notice.

This manual represents the series status of the vehicle on the copy deadline date.

K 90

0.10 - 1

ELECTRICAL SYSTEM

Contents
Electrical system ...........................................................................................................................	0
Preface..........................................................................................................................................	0.10 - 1
Contents........................................................................................................................................	0.11 - 1
Abbreviations ................................................................................................................................	0.13 - 1
General remarks ............................................................................................................................	1
Safety notes ..................................................................................................................................	1.20 - 1
Instructions for the use of wiring diagrams ...................................................................................	1.60 - 1
Search criteria ...............................................................................................................................	1.99 - 1
Series wiring diagrams .................................................................................................................	3
Contents........................................................................................................................................	3.00 - 1
Additional wiring diagrams ..........................................................................................................	4
Contents........................................................................................................................................	4.00 - 1

K 90

0.11 - 1

ELECTRICAL SYSTEM

Abbreviations		As of: 11.01
a	Acceleration
ABE	General operating permit
ABS	Anti-lock brake system
ABV	Anti-skid system
AC	Air conditioning
ACC	Adaptive cruise control
ACK	Autocheck
ADC	Analog-digital converter
ADR	International agreement for the transport of dangerous goods
AGB	Automatic road speed limiter
AGND	Analog ground
AGR	Exhaust gas recirculation (EGR)
AHK	Trailer coupling
AHV	Trailer brake valve
ALB	Automatic load-dependent brake
AMA	Antenna mast system
ANH	Trailer/semitrailer
AS	Automated gearbox
ASD	Trailer socket
ASM	Trailer control module
ASR	Anti-spin regulator
ASV	Trailer control valve
ATC	Automatic temperature control
ATF	Automatic transmission fluid
AU	Emission test
AV	Exhaust valve
AVS	Automatic gear preselection
BA	Operator's manual
BBA	Service brake system
BBV	Service brake valve
BKR	Brake power regulator
BUGH	Front heater
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
CAN-H	CAN-high data line
CAN-L	CAN-low data line
CATS	Computer-assisted testing and diagnostic system
CCVS	Cruise control vehicle speed
CKD	Completely knocked down
CNG	Compressed natural gas
CPU	Central processing unit
CRT	Continuously regenerating trap
CS	Comfort shift
DAHL	Roof ventilator
DBR	Auxiliary brake relay
DECKE	Cover (for doors)
DF	Speed sensor
DFÜ	Data transmission
DIA	Diagnosis and information display

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ELECTRICAL SYSTEM

Abbreviations

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 EDC/EMS pedal value sensor)
DLB	Compressed air brake system
DM	Diagnostic message
DNR	Drive – Neutral – Reverse (selector switch for automatic gearbox)
DPF	Diesel particulate filter
DRM	Pressure control module
DS	Pressure sensor
DSV	Pressure control valve
DV	Throttle valve
DWA	Anti-theft protection system
DZG	Rpm sensor
DZM	Rev counter
EBS	Electronic brake 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 meter
EDR	Maximum speed governor
EEC	Electronic engine controller
EEPROM	Electrically erasable and programmable read-only memory
EFR	Electronic shock absorber control (ESAC)
EFS	Electrical driver's seat
EHAB	Electro-hydraulic 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)
ESAC	Electronic shock absorber control
ESP	Electronic stability program
ESR	Electric sun-blind
EST	Electronic control unit
EV	Intake valve
EVB	Exhaust valve brake
FAP	Driver's area
FAQ	Frequently asked questions
FBA	Parking brake system
FDR	Dynamic handling control
FFR	Vehicle management computer (VMC)
FGB	Road speed limiter (RSL)
FGR	Road speed governor (RSG)
FHS	Cab
FIN	Vehicle identification number (VIN)
FM	Vehicle management
FMI	Failure mode identification

0.13 - 2

K 90

ELECTRICAL SYSTEM

Abbreviations

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
GDK	Controlled diesel catalytic converter
GEN	Alternator
GET	Gearbox
GGVS	Regulations for the transport of hazardous goods
GND	Ground
GP	Gearbox planetary gear group (range-change box)
GS	Gearbox control
GV	Gearbox splitter gear group (splitter box)
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 control panel
HU	Main inspection
Hz	Hertz (number of cycles per second)
HZA	Bus stop indicator system
HZG	Auxiliary rpm sensor
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
KBZ	Combination brake cylinder
KFH	Fuel filter heater
KITAS	Kienzle intelligent tachograph sensor
KLI	Air-conditioning system
KNEEL	Kneeling
KSM	Customer-specified control module
KSW	Customer’s special request
KWP	Key word protocol (protocol for MAN-cats diagnosis)
LBH	Air reservoir
LCD	Liquid crystal display
LDA	Manifold-pressure compensator (boost control)
LDF	Boost pressure sensor
LDS	Air spring/damper system
LED	Light emitting diode
LF	Air suspension
LGS	Lane guard system

K 90

0.13 - 3

ELECTRICAL SYSTEM

Abbreviations

LL	Idling speed
LLA	Idling speed increase
LLR	Idling speed control
LNG	Liquified natural gas
LOE	Steering oil monitor
LPG	Liquified petroleum gas
LWR	Headlight beam regulator
M-TCO	Modular EU tachograph
MAB	Solenoid valve shut-off (engine shut-off by means of 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	Fuel metering control
ML	Midline
MMI	Man-machine interface
MOTB	Engine brake
MP	Engine power box (cable duct on engine block)
MR	Engine governor – ASR
MSG	Engine control unit (EDC)
MV	Solenoid valve
MZ	Diaphragm cylinder
n	rpm
NA	Power take-off (PTO)
NBF	Needle movement sensor
NES	New electronic structure
NFZ	Commercial vehicle
NLA	Trailing axle
NSL	Rear fog lamp
NSW	Front fog lamp
OBDU	On-board diagnostic unit
OC	Occurrence count (errors/faults)
OEAB	Oil separator
OENF	Oil top-up
p	Pressure
PBM	Pulse breadth modulation ( also see PWM)
PLM	Programmable logic module
PSG	Pump control unit (EDC)
PTO	Power take-off
PWM	Pulse width modulation ( also see PBM)
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

0.13 - 4

K 90

ELECTRICAL SYSTEM

Abbreviations

SA	Special equipment
SAE	Society of Automotive Engineers
SAMT	Semi-automatic mechanical transmission
SB	Service outlet
sec	Second
SER	Series (production)
SG	Control unit
SH	Select-high control (ABS)
SKD	Semi-knocked down
SL	Select-low control (ABS)
SML	Side marker light
SPN	Suspect parameter number
STA	Engine start/stop
SWR	Headlight cleaning system
t	Time
TC	Traction control
TCM	Trailer control module
TCO	Tachograph
TKU	Technical customer document
TMC	Traffic message channel
TRS	Technical road transport directives
TSC	Torque speed control (braking torque)
TUER	Door control
UBat	Battery voltage
UDS	Crash recorder
v	Velocity/vehicle speed
VA	Front axle
VG	Transfer case
VLA	Leading axle
WA	Maintenance manual
WAB	Water separator
WLE	Swap-body unit
WR	Warning relay
WS	Position sensor
WSK	Torque converter and clutch unit
z	Braking rate/deceleration
ZBR	Central on-board computer
ZBRO	Central on-board bus computer
ZDR	Intermediate speed governor (ISG)
ZE	Central electrical system (CES)
ZR	Central computer
ZS	Central lubrication
ZUSH	Auxiliary heater
ZWS	Time-based maintenance system
λ	Slipµ	Coefficient of friction
µC	Microcontroller (microprocessor)

K 90

0.13 - 5

GENERAL INFORMATION

Notes on safety

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.

Additional instructions are included in the Operator's Manual that is provided with 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 allowed 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 allowed to start and operate the engine.

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

∙Do not touch the engine with your bare hands when it is at operating temperature: Risk of burns!

∙ Keep the area around the engine, ladders and steps free from oil and grease. Accidents caused by slipping can have 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 emerges. Treat brake fluid as hazardous waste! Comply with the safety regulations for preventing environmental pollution.

∙ Brake fluid is toxic! 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. If it does need to be opened whilst the engine is at operating temperature, follow the instructions in the “Maintenance and care” section in the Operator's Manual.

∙Do not attempt to retighten or open pipe lines and hoses (lubricating oil circuit, coolant circuit and possible 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.

K 90

1.20 - 1

GENERAL INFORMATION

∙ Always disconnect the batteries before working on the vehicle 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 and 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 for handling batteries.

∙Measure voltage only using suitable measuring devices!

The input resistance of a measuring device should be at least 10 MΩ.

∙The ignition must be switched off before the wiring harness plugs of electronic control units are disconnected or connected up!

When performing electrical welding work, connect up the “ANTIZAP SERVICE MONITOR” (MAN item number 80.78010.0001) or the improved SES-1 version (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 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 cables to the welding equipment in parallel to electrical cables in the vehicle.

For further accident prevention measures, please refer to the “Leaflets for welders”.

The frame is not intended for use as an earth return!

∙If attachments are to be retrofitted to the vehicle – e.g. a taillift – additional earth lines with 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.

∙If painting work is to be carried out, do not expose the electronic components to high temperatures (max. 95 °C) for more than bri ef periods; a time of up to around 2 hours is permissible at a maximum of 85 °C . Disconnect the batteries.

Plastic tubes (polyamide)

Important! – Risk of damage and fire!

∙The warning sign opposite can be found on the co-driver's door below the door lock. It warns you against welding or drilling near to plastic tubes.

1.20 - 2	K 90

GENERAL INFORMATION

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 for your MAN vehicle. 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 technica l inspection authorities or some other official body.

Bodies and special attachments

Comply with the safety instructions and regulations issued by the bodymaker in question if bodies or special attachments 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.

K 90

1.20 - 3

GENERAL REMARKS

Instructions for using wiring diagrams

1Name of component (here: diode V100 on the central fuse, relay and terminal box (“ZE”), position 53)

2Mounting position on the front panel of the central fuse, relay and terminal box (“ZE”) (here: engraved position number 53)

3Plug connector on the rear of the central fuse, relay and terminal box (“ZE”) (here: plug 78, connection 8)

4Cable number; printed on the cable at short intervals (cross-section only if greater than 12)

5Sheet number (not page number) and circuit number

Marking to show on which sheet and circuit the conductor continues (here: continuation of conductor 31002 on sheet 2 on circuit 4)

6Plug connector (here: single-pin connector X104 in the ZE area)

7Component mounting position (here: 21-pin connector X238 Pin R

– wiring harness cab to engine – in central portion)

8Circuit number (please note: sheets are numbered consecutively from 1 to 55)

Important note on the use of the wiring diagram legends: A three-digit number is shown in brackets after various item numbers. This number is the coded part number for this component!

These part numbers can be found in the T60 device list.

K 90

1.60 - 1

GENERAL REMARKS

Mounting positions for left-hand drive

1.60 - 2

K 90

GENERAL REMARKS

Marks

Mounting position

............................................................................................................. Tail

............................................................................................................. Engine

............................................................................................................. Gearbox

............................................................................................................. Front

............................................................................................................. Bumper

............................................................................................................. Entrance right

............................................................................................................. Entrance left

............................................................................................................. Central electrics area

............................................................................................................. Control unit racks

............................................................................................................. Rear wall of cab

............................................................................................................. Instrument panel

............................................................................................................. Central part

............................................................................................................. Steering wheel/column

............................................................................................................. Foot pedals

............................................................................................................. Front wall, inside left

............................................................................................................. Front wall, inside right

............................................................................................................. Driving seat

............................................................................................................. Passenger seat

............................................................................................................. Control panel

............................................................................................................. Battery box

............................................................................................................. B-pillar on driver's side

............................................................................................................. A-pillar on driver's side

............................................................................................................. B-pillar on passenger's side

............................................................................................................. A-pillar on passenger's side

............................................................................................................. Ceiling/roof

............................................................................................................. Front axle

............................................................................................................. Rear axle

............................................................................................................. Front parts of frame

............................................................................................................. Rear part of frame

............................................................................................................. Door left

............................................................................................................. Door right

K 90

1.60 - 3

GENERAL REMARKS

Mounting positions for right-hand drive

1.60 - 4

K 90