MAN TGX K100, TGS K100 Wiring Diagram

Electrical System

06S-1580, 06S-1581 89S-0161, 89S-0162

26X-0150, 28X-0006, 30X-0273

TGS/TGX

Copy deadline: 03.2010

Wiring Diagrams

81.99298-6602 2nd edition K100

MAN Nutzfahrzeuge Aktiengesellschaft Dachauer Str . 667 80995 MÜNCHEN oder Postfach 50 06 20 80976 MÜNCHEN

Schaltpläne K100, 2. Ausgabe

Elektrische Anlage

TGS/TGX

- Englisch -

Printed in Germany

Wiring Diagrams K100

2nd edition

Electrical System

TGS/TGX 06S-1580, 06S-1581 89S-0161, 89S-0162 26X-0150, 28X-0006, 30X-0273

81.99298-6602

PREF ACE/PRINTER'S IMPRINT

PREF ACE

The "Wiring Diagrams" manual documents the entire scope of series standard and additional wiring diagrams.

The series standard wiring diagrams and the additional wiring diagrams are illustrated with a detailed key and current path designations.

This manual is based on wiring diagrams created using CAD. This means the manual is quick and easy to update.

This manual describes the standard production version of your vehicle as at the copy deadline.

CAUTION T ype and source of danger

• Refers to working and operating procedures which must be followed exactly in order to avoid exposing people to risk.

W ARNING T ype and source of danger

• Refers to working and operating procedures which must be followed exactly in order to avoid serious or irreparable damage to property .

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

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

2010 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 modication. Furthermore, MAN Nutzfahrzeuge AG shall not be liable for any damage resulting from the unapproved modication.

Redaktion: SA WET -Y / HA 03.2010

Satz: SA WET -Y

Druck: MAN-W erksdruckerei

2 K100 2nd edition

T ABLE OF CONTENTS

Content Chapter/Page

Index 7

Abbreviations 9

Introduction

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

Overview of models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Explanatory notes to the wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Series standard wiring diagram

wiring diagram No. 81.99192.3079 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

A = V oltage supply , starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 22 . . . . . . . . . . 26

A = On-board computer voltage supply / B = EBS voltage supply / C = V ehicle

management computer voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 22 . . . . . . . . . . 28

A = Chassis earth distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 3 of 22 . . . . . . . . . . 30

A = On-board diagnosis (OBD) diagnosis socket / B = ZDR interface (FFR)

(MDB, HGB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 4 of 22 . . . . . . . . . . 32

A = Flame start system / B = Fan clutch / C = EDC coolant temperature / D =

Coolant level / E = Air lter pressure sensor / F = Power steering oil level . . . . . sheet 5 of 22 . . . . . . . . . . 34

A = Probe for clutch uid level / B = Multifunctional steering wheel / C = Steering column stalk / D = Sustained-action brake / E = Distributor , line

60028 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 6 of 22 . . . . . . . . . . 36

A = Air dryer/brake circuit monitoring / B = Cab lock check / C = Fuel gauge . sheet 7 of 22 . . . . . . . . . . 38

A = Signal horn / B = Fuel lter heater preparation / C = Engine brake / D =

Oil level sensor / E = M-CAN / F = Outside temperature . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 8 of 22 . . . . . . . . . . 40

A = Heater blower/air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 9 of 22 . . . . . . . . . . 42

A = W ashers and wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 10 of 22 . . . . . . . . 44

A = Immobiliser / B = Gear selector lever / C = V ehicle management computer

diagnosis / D = Accelerator pedal unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 1 of 22 . . . . . . . . 46

A = V oltage supply +15 / B = Instrumentation/tachograph . . . . . . . . . . . . . . . . . . . . . . . . sheet 12 of 22 . . . . . . . . 48

A = Lighting learning routine / B = Light circuit / C = Fog lamp/rear fog lamp

circuit / D = Cigarette lighter / E = Ashtray lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 13 of 22 . . . . . . . . 50

A = Parking lights, left / B = Parking lights, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 14 of 22 . . . . . . . . 52

A = Headlight ash / B = Headlight low beam, headlight high beam, daytime

driving lights / C = Headlight beam regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 15 of 22 . . . . . . . . 54

A = Rear fog lamps / B = Fog lamps, additional high beam headlights, cornering light, left / C = Fog lamps, additional high beam headlights,

cornering light, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 16 of 22 . . . . . . . . 56

A = Brake light / B = Parking brake / C = Reversing light . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 17 of 22 . . . . . . . . 58

A = Pushbutton unit illumination / B = Permanent load voltage supply / C =

Entrance lighting / D = Interior lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 18 of 22 . . . . . . . . 60

A = T urn indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 19 of 22 . . . . . . . . 62

A = Spare lines / B = Spare lines for trailer socket / C = Spare lines for engine

start/stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 20 of 22 . . . . . . . . 64

A = Gearbox / B = T -CAN network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 21 of 22 . . . . . . . . 66

A = Intarder , retarder / B = Power take-of f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 22 of 22 . . . . . . . . 68

Additional wiring diagrams

wiring diagram No. 81.99192.2496 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

T railer socket 24V 7-pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . . 72

wiring diagram No. 81.99192.2498 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

T railer socket 24V 7-pole/7-pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . . 74

wiring diagram No. 81.99192.1358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

ASR check lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . . 76

wiring diagram No. 81.99192.3222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

K100 2nd edition 3

T ABLE OF CONTENTS

ASR slip thresholds button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . . 78

wiring diagram No. 81.99192.2495 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Battery master switch, mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . . 80

wiring diagram No. 81.99192.3235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Interaxle and transverse dif ferential lock, rear axle (3-axle vehicle) . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . . 82

wiring diagram No. 81.99192.3233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

T ransverse dif ferential lock, rear axle (2-axle vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . . 84

wiring diagram No. 81.99192.3246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Electronic Brake System EBS 5 (2-axle vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 3 . . . . . . . . . . . 86

Electronic Brake System EBS 5 (2-axle vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 3 . . . . . . . . . . . 88

Electronic Brake System EBS 5 (2-axle vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 3 of 3 . . . . . . . . . . . 90

wiring diagram No. 81.99192.3247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Electronic Brake System EBS 5 (3-axle vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 4 . . . . . . . . . . . 92

Electronic Brake System EBS 5 (3-axle vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 4 . . . . . . . . . . . 94

Electronic Brake System EBS 5 (3-axle vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 3 of 4 . . . . . . . . . . . 96

Electronic Brake System EBS 5 (3-axle vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 4 of 4 . . . . . . . . . . . 98

wiring diagram No. 81.99192.3250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

ECAS 2 (4x2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 2 . . . . . . . . . . 100

ECAS 2 (4x2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 2 . . . . . . . . . . 102

wiring diagram No. 81.99192.3248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

ECAS 2 (4x2 - semitrailer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 2 . . . . . . . . . . 104

ECAS 2 (4x2 - semitrailer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 2 . . . . . . . . . . 106

wiring diagram No. 81.99192.3253 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

ECAS 2 (6x2 optionally with ALM/crane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 2 . . . . . . . . . . 108

ECAS 2 (6x2 optionally with ALM/crane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 2 . . . . . . . . . . 1 10

wiring diagram No. 81.99192.3624 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 12

EDC7 Euro 3 D20... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 3 . . . . . . . . . . 1 12

EDC7 Euro 3 D20... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 3 . . . . . . . . . . 1 14

EDC7 Euro 3 D20... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 3 of 3 . . . . . . . . . . 1 16

wiring diagram No. 81.99192.3625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 18

EDC7 Common Rail Euro 3 D2676 LF , E-EGR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 4 . . . . . . . . . . 1 18

EDC7 Common Rail Euro 3 D2676 LF , E-EGR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 4 . . . . . . . . . . 120

EDC7 Common Rail Euro 3 D2676 LF , E-EGR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 3 of 4 . . . . . . . . . . 122

EDC7 Common Rail Euro 3 D2676 LF , E-EGR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 4 of 4 . . . . . . . . . . 124

wiring diagram No. 81.99192.3617 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Electric cab tilt mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 126

wiring diagram No. 81.99192.3260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

EVB, controlled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 128

wiring diagram No. 81.99192.3173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Cab, T -CAN, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 130

wiring diagram No. 81.99192.3267 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Window lifter , button in shift console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 132

wiring diagram No. 81.99192.3276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Gearbox / manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 2 . . . . . . . . . . 134

Gearbox / manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 2 . . . . . . . . . . 136

wiring diagram No. 81.99192.3748 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Gearbox / manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 2 . . . . . . . . . . 138

Gearbox / manual gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 2 . . . . . . . . . . 140

wiring diagram No. 81.99192.1374 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Seat belt indicator , driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 142

wiring diagram No. 81.99192.3292 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

T railer charge, 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 144

wiring diagram No. 81.99192.3237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

I-CAN cab (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 146

wiring diagram No. 81.99192.3405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

I-CAN roof (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 148

wiring diagram No. 81.99192.3293 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Interior lighting, roof, white/red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 150

wiring diagram No. 81.99192.3461 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Interior lights with ambient light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 152

wiring diagram No. 81.99192.3295 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

4 K100 2nd edition

T ABLE OF CONTENTS

Intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 154

wiring diagram No. 81.99192.3043 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

T achograph check lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 156

wiring diagram No. 81.99192.3304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Fuel lter heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 158

wiring diagram No. 81.99192.3305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Fuel lter heater , Separ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 160

wiring diagram No. 81.99192.3300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Customer-specic control module (KSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 2 . . . . . . . . . . 162

Customer-specic control module (KSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 2 . . . . . . . . . . 164

wiring diagram No. 81.99192.3314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Headlight beam regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 166

wiring diagram No. 81.99192.3120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Fan clutch with speed feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 168

wiring diagram No. 81.99192.1656 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 170

wiring diagram No. 81.99192.3316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Engine brake, automatic, of f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 172

wiring diagram No. 81.99192.3501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Multifunctional steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 174

wiring diagram No. 81.99192.3366 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Fog lamps/additional high beam headlights and cornering light . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 176

wiring diagram No. 81.99192.3337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Pritarder/Intarder , automatic, of f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 178

wiring diagram No. 81.99192.3134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Basicline radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 180

wiring diagram No. 81.99192.3490 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

T opline radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 2 . . . . . . . . . . 182

T opline radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 2 . . . . . . . . . . 184

wiring diagram No. 81.99192.3349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Bunk light, bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 186

wiring diagram No. 81.99192.2592 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Side marker lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 188

wiring diagram No. 81.99192.3298 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Seat heating, driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 190

wiring diagram No. 81.99192.3313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

V oltage transformer , 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 192

wiring diagram No. 81.99192.3317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

ST AR T/ST OP device on engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 194

wiring diagram No. 81.99192.3395 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Storage locker lighting, rear left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 196

wiring diagram No. 81.99192.3396 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Storage locker lighting, rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 198

wiring diagram No. 81.99192.3350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Storage locker lighting, top (left, middle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 200

wiring diagram No. 81.99192.3351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Storage locker lighting, top (left, middle, right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 202

wiring diagram No. 81.99192.3367 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Sockets in cab, 12V and 24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 204

wiring diagram No. 81.99192.3082 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Anti-jackknife brake for EBS5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 206

wiring diagram No. 81.99192.3221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

T -CAN terminating resistor in cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 208

wiring diagram No. 81.99192.3174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

T -CAN standard/ECAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 210

wiring diagram No. 81.99192.3175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

T -CAN standard/ECAS/Intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 212

wiring diagram No. 81.99192.3178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

T -CAN standard/Intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 214

wiring diagram No. 81.99192.3180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

T -CAN (KSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 216

K100 2nd edition 5

T ABLE OF CONTENTS

wiring diagram No. 81.99192.3077 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Door module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 5 . . . . . . . . . . 218

Door module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 2 of 5 . . . . . . . . . . 220

Door module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 3 of 5 . . . . . . . . . . 222

Door module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 4 of 5 . . . . . . . . . . 224

Door module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 5 of 5 . . . . . . . . . . 226

wiring diagram No. 81.99192.3303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Preparation, transverse dif ferential lock, rear axle (2-axle vehicle) . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 228

wiring diagram No. 81.99192.3379 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Preparation, central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 230

wiring diagram No. 81.99192.3352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sheet 1 of 1 . . . . . . . . . . 232

6 K100 2nd edition

INDEX

Catchword Page

Numeric/Symbols

81.99192.1358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

81.99192.1374 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

81.99192.1656 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

81.99192.2495 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

81.99192.2496 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

81.99192.2498 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

81.99192.2592 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

81.99192.3043 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

81.99192.3077 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

81.99192.3079 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

81.99192.3082 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

81.99192.3120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

81.99192.3134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

81.99192.3173 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

81.99192.3174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

81.99192.3175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

81.99192.3178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

81.99192.3180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

81.99192.3221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

81.99192.3222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

81.99192.3233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

81.99192.3235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

81.99192.3237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

81.99192.3246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

81.99192.3247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

81.99192.3248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

81.99192.3250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

81.99192.3253 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

81.99192.3260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

81.99192.3267 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

81.99192.3276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

81.99192.3292 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

81.99192.3293 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

81.99192.3295 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

81.99192.3298 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

81.99192.3300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

81.99192.3303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

81.99192.3304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

81.99192.3305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

81.99192.3313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

81.99192.3314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

81.99192.3316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

81.99192.3317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

81.99192.3337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

81.99192.3349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

81.99192.3350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

81.99192.3351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

81.99192.3352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

81.99192.3366 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

81.99192.3367 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

81.99192.3379 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

81.99192.3395 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

81.99192.3396 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

81.99192.3405 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

81.99192.3461 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

81.99192.3490 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

81.99192.3501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

81.99192.3617 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

K100 2nd edition 7

INDEX

81.99192.3624 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 12

81.99192.3625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 18

81.99192.3748 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

8 K100 2nd edition

LIST OF ABBREVIA TIONS

Abbreviations

a Acceleration ABE General certication ABS Anti-lock 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 T railer coupling AHV T railer brake valve ALB Automatic load balancing ALM Axle Load Monitoring AMA Antenna mast system AMR Anisotropic Magneto-Resistance ANH T railer / semitrailer AS Automatic gearbox ASD T railer socket ASM T railer control module ASR Anti-spin regulator (traction control) ASV T railer control valve A TC Automatic T emperature Control A TF Automatic T ransmission Fluid AU Statutory exhaust emission test A V Exhaust valve A VS Automatic gear preselection

BA Operator's manual BBA Service brake system BBV Service brake valve BITE Built-in test equipment BKR Brake power regulator BUGH Front heater BV Backup valve BV A Brake wear indicator BVS Brake wear sensor BVV Brake wear sensor supply BW German Army BWG Brake power sensor BZ Brake cylinder

CAN Controller Area Network (data bus system with serial bit transmission) CAN-H CAN-high data line CAN-L CAN-low data line CA TS Computer-assisted testing and diagnostic system CBU Central Brake Unit CDC Continuous Damping Control CCVS Cruise control vehicle speed CKD Completely Knocked Down CNG Compressed Natural Gas CPU Central Processing Unit CR T Continuously Regenerating T rap (exhaust muf er , two-way catalytic converter , diesel particulate

lter)

K100 2nd edition 9

LIST OF ABBREVIA TIONS

CRC Cyclic Redundancy Check CS Comfort Shift

DAHL Roof ventilator DBR Sustained-action brake relay DCU Dosing Control Unit (AdBlue dosing) DF Speed sensor DFÜ Data transmission DIA Diagnosis and information display DIAG Diagnosis, entire vehicle DIAG MUX 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 aps DKR Throttle valve reduction (reduction request from ASR to EDC / EMS) DKV Throttle valve specication (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 DRS Rotational speed sensor DS Pressure sensor DSV Pressure control valve DTC Diagnostic T rouble Code (OBD fault code) DTCO Digital tachograph DV Throttle valve DW A Anti-theft warning system DZG Speed sensor DZM Rev counter

Diagnosis, entire vehicle – Multiplex central computer (buses only)

EBS Electronic Brake System ECAM Electronically Controlled Air Management ECAS Electronically Controlled Air Suspension ECE Emergency shut-of f to ECE 36 ECU Electronic Control Unit EDC Electronic Diesel Control EDC S Electronic Diesel Control Slave 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 Electric driver's seat EHAB Electro-hydraulic shut-of f device ELAB Electrical shut-of f 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

10 K100 2nd edition

ESR Electric sun-blind EST Electronic control unit EV Intake valve EVB Exhaust V alve Brake

F AP Driver's area F AQ Frequently Asked Questions FBA Parking brake system FBM Pedal brake module FDR Dynamic handling control FDF V ehicle data le FFR V ehicle management computer FGB Road speed limiter (RSL) FGR Road speed governor (RSG) FHS Cab FIN V ehicle identication number (17 digits) FM V ehicle management FMI Failure Mode Identication FMS Fleet Management Standard (global telematics standard) FMR V ehicle/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 V ehicle number (7 digits)

LIST OF ABBREVIA TIONS

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)

HA Rear axle HBA Auxiliary brake system HD-OBD Heavy Duty On-Board Diagnosis HDS Urea dosing 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 HYD Hydronic auxiliary heater HYDRIVE Hydrostatic front-wheel drive HYDRO MAN Hydro Drive HV A Hydrostatic front-wheel drive Hz Hertz (number of cycles per second) HZA Bus stop indicator system HZG Auxiliary speed sensor

K100 2nd edition 1 1

LIST OF ABBREVIA TIONS

IBEL Interior lighting IBIS Integrated on-board information system IC Integrated Circuit ID Identication IMR Integrated Mechanical Relay (starter control) INA Information lamp (e.g. check lamp) INST Instrumentation IR Individual control (ABS) IRM Modied individual control (ABS) ISO International Standards Organisation IWZ Incremental angle/time measuring system

KBZ Combination brake cylinder KFH Fuel lter heater KIT AS Kienzle intelligent tachograph sensor KLI Air-conditioning system KNEEL Kneeling KSM Customer-specied control module (control unit for external data exchange) KSW Customer's special request KWP Key W ord 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 LL Idling speed LLA Idling speed increase LLR Idling speed control LNA Steering trailing axle LNG Liqueed Natural Gas LOE Steering oil monitor LPG Liqueed Petroleum Gas LSV A Distance-based heavy vehicle toll L WR Headlight beam regulator L WS Steering angle sensor

M-TCO Modular EU tachograph MAB Solenoid valve shut-of f (engine shut-of f by high-pressure solenoid valve in injection pump) MAN- cats MAN computer-assisted testing and diagnostic system MAR Solenoid valve shut-of f relay (redundant engine shut-of f relay) MDB Engine speed range MES Quantity positioner MFL Multifunctional steering wheel 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) MUX Multiplex central computer (bus only) MV Solenoid valve MZ Diaphragm cylinder

12 K100 2nd edition

n Speed (rpm) NA Power take-of f NBF Needle movement sensor NES New Electronic Structure NFZ Commercial vehicles NLA T railing axle NSL Rear fog lamp NSW Fog lamps

OBD On-Board Diagnosis OBDU Onboard Diagnostic Unit (subsystem of central on-board computer) OC Occurrence Count (frequency counter of an error) OEAB Oil separator OENF Oil top-up

p Pressure PBM Pulse Breadth Modulation (also see PWM) P-Code Powertrain code (power pack/powertrain fault code) PDF Particulate Diesel Filter PLM Programmable Logic Module PM-Kat Particulate matter catalytic converter (particulate catalytic converter) PSG Pump control unit (EDC) PTM Powertrain Manager (replacement for vehicle management computer) PT O Power T ake-Of f PWG Pedal value sensor PWM Pulse Width Modulation (also see PBM)

LIST OF ABBREVIA TIONS

RA Repair manual RAH Interior heating RAM Random Access Memory RAS Rear Axle Steering RAS-EC Rear Axle Steering with Electronic Control RDRA T yre pressure control system RDS Radio Data System RET Retarder RET P Primary retarder RET S Secondary retarder RKL Priority vehicle light RKS T yre pressure monitor RL V Relay valve RME Rape seed oil methyl ester (biodiesel) ROM Read Only Memory

SA Special equipment SAE Society of Automotive Engineers SAMT Semi-automatic mechanical transmission SB Service outlet SBW -RA Steer By Wire Rear Axle (electronically controlled steering trailing axle) SCR Selective Catalytic Reduction 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

K100 2nd edition 13

LIST OF ABBREVIA TIONS

ST A Engine start/stop SWR Headlight cleaning system

t T ime TBM On-board telematics module TC T raction Control TCM T railer Control Module TCO T achograph (MTCO, DTCO, TSU etc.) TCU T ransmission Control Unit TEPS T win Electronic Platform Systems (bus only) TGA T rucknology Generation A TGL T rucknology Generation Light TGM T rucknology Generation Mid TKU T echnical customer document TMC T raf c Message Channel TPM T yre Pressure Module TRS T echnical road transport directive TSC T orque Speed Control TSU T achograph Simulating Unit (vehicles without MTCO/DTCO) TUER Door control

B a t

Battery voltage UDF Conversion le UDS Crash recorder

v Road speed V A Front axle VDF V ehicle Data File VG T ransfer case or according to defence equipment standards VLA Leading axle VSM T ransfer case lock management

W A Maintenance Manual W AB W ater separator W aPu W ater pump Intarder WLE Swap-body unit WR W arning relay WS Position sensor WSK T orque 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 ZFR Auxiliary vehicle computer ZR Central computer ZS Central lubrication system ZUSH Auxiliary heater ZWS T ime-based maintenance system λ Slip µ Coef cient of friction µC Microcontroller (microprocessor)

14 K100 2nd edition

INTRODUCTION

SAFETY INSTRUCTIONS

General information

W orking with trucks, buses and the accompanying service products should not pose any problems if operators, maintenance personnel and repair staf f 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 direct references to danger are contained in the instructions at points where there is a potential danger .

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

W orking on the brake system – Perform visual, function and ef fectiveness 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 uid as it drains out. – Hydraulic oil/brake uid is poisonous!

Do not allow brake uid to come into contact with food or open wounds.

– T reat hydraulic oil/brake uid as hazardous waste!

Comply with the safety regulations for preventing environmental pollution.

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.

K100 2nd edition 15

INTRODUCTION

Suspended loads – No-one is allowed to stand under a unit suspended from a crane hook. - Keep all

lifting tackle in good condition -

W orking 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.

W orking on the vehicle electrical system – Always disconnect the batteries before working on the electrical system.

Disconnect the earth cable rst 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.

– T ow-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 of f 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. T ake 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!

– A void 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! – W ear appropriate protective clothing (gloves, protective apron) when handling

batteries. Do not tilt batteries, acid may leak out.

16 K100 2nd edition

Electric welding – Connect up the "ANTIZAP SER VICE MONIT OR" 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

tted to the vehicle (e.g. a taillift), additional earth (ground) lines with an adequate cross-section must be tted 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.

W orking on plastic tubes - Danger of damage and re! – The warning sign opposite is attached to the inside of the diesel fuel or heating oil

tank ap. It warns you against welding or drilling near to plastic tubes.

INTRODUCTION

W orking 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 nal position.

W orking on the air-conditioning system – Refrigerant uids and vapours represent a health hazard, avoid contact with them

and protect your eyes and hands.

– Do not drain gaseous refrigerants in enclosed rooms. – 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.

– Always use genuine 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 lled with oil before running it. – Never run engines without coolant. – Apply a suitable information sign to units that are not ready to be operated.

K100 2nd edition 17

INTRODUCTION

– Only use service products (engine and gearbox oil as well as antifreeze and anti-corrosion protection) that

have been approved by MAN. Keep your workplace clean.

– Comply with the specied maintenance intervals. – Do not ll 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 specically 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 of cially approved by the German TÜV technical inspection authorities or some other of cial 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 tted. Always follow the instructions in the appropriate MAN Guide to Fitting Bodies (www .manted.de). W ritten approval/release/conrmation from department TDB is required if the appropriate MAN Guide to Fitting Bodies is not complied with.

T aking out of operation and storing

The special measures described in MAN W orks 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 are machined, in particular during skimming and grinding

as well as 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 ef cient ventilation

system.

– If possible, use hand-operated or slow-running tools, equipped with a dust-collector if required. – Fast-running tools should always be tted 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

T reat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority when disposing of used coolant (mixture of antifreeze and water).

Cleaning the cooling circuit

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

Cleaning the lter insert

When blowing compressed air through the lter insert, make sure the lter dust is collected by a vacuum or is blown into a dust collection bag. Otherwise, use a respiratory protection mask. W ear rubber gloves or use a skin barrier hand cream when washing out the insert, because cleaning agents have aggressive grease-dissolving characteristics.

Engine/gear oil, lter cartridges, elements and box-type lters, 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 lters (oil and fuel lters, desiccant cartridges for the air dryer) are classied as hazardous waste materials and must be disposed of properly . Please follow the instructions of your 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 inammation. In addition to these hazards, used engine oil contains dangerous materials which can cause skin cancer .

18 K100 2nd edition

INTRODUCTION

6. Health protection precautions – A void 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. – W ash the areas thoroughly with soap and water . – A nail brush enables more ef fective cleaning. – 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. T ake 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 T raders’ Association (MINERALÖL WIR TSCHAFTSVERBAND E.V .) Steindamm 71, D-20099 Hamburg

K100 2nd edition 19

INTRODUCTION

OVER VIEW OF MODELS

These wiring diagrams - 03.2010 edition - apply to the following vehicles.

Model Model designation Model Model designation

Model

06S -

1580

26X - 0150

28X - 0006

30X - 0273

Model

06S -

1581

TGX 26/33.D20/D26 6X4 BB

TGX 28 6X4 BB-CKD

TGX 26/33.D20/D26 6X4 BL

Model

89S -

0161

Model

89S -

0162

Model

26X -

0150

Model

28X -

0006

06S - 1580 TGS 18.D20/D26 4X2 BL

06S - 1581 TGS 18.D20/D26 4X2 BL

89S - 0161 TGS 28.D20/D26 6X2-2 BL

89S - 0162 TGS 28.D20/D26 6X2-2 BL

Overview of wiring diagrams classied according to model designation

Name Item no.:

ASR check lamp

Seat belt indicator , driver

Engine brake 81.99192.1656 X X X X X X

Battery master switch, mechanical

T railer socket 24V 7-pole 81.99192.2496 X

T railer socket 24V 7-pole 81.99192.2498 X X X X X X

Side marker lights

T achograph check lamp 81.99192.3043 X X X X X X X

81.99192.1358 X X X X

81.99192.1374 X X X X X X X

81.99192.2495 X

81.99192.2592 X X X X X

Model

30X -

0273

Door module 81.99192.3077 X X X X X X X

Series standard wiring diagram

Anti-jackknife brake for EBS5

Fan clutch with speed feedback

Basicline radio 81.99192.3134 X X X X X X

Cab, T -CAN, standard

T -CAN standard/ECAS

T -CAN standard/ECAS /Intarder

T -CAN standard/Intarder

T -CAN (KSM)

T -CAN terminating resistor in cab

ASR slip thresholds button

T ransverse dif ferential lock, rear axle (2-axle vehicle)

Interaxle and transverse dif ferential lock, rear axle (3-axle vehicle)

81.99192.3079 X X X X X X X

81.99192.3082 X

81.99192.3120 X X

81.99192.3173 X

81.99192.3174 X X

81.99192.3175 X X X

81.99192.3178 X

81.99192.3180 X X X X X X

81.99192.3221 X X X X X X X

81.99192.3222 X X X X

81.99192.3233 X X

81.99192.3235 X X X

I-CAN cab (standard)

Electronic Brake System EBS 5 (2-axle vehicle)

20 K100 2nd edition

81.99192.3237 X X X X X X X

81.99192.3246 X X

INTRODUCTION

Model

Name Item no.:

Electronic Brake System EBS 5 (3-axle vehicle)

ECAS 2 (4x2 - semitrailer)

ECAS 2 (4x2)

ECAS 2 (6x2 optionally with ALM/crane)

EVB (Exhaust V alve Brake), controlled

Window lifter , button in shift console

Gearbox / manual gearbox

T railer charge, 24V 81.99192.3292 X

Interior lighting, roof, white /red

81.99192.3247 X X X X X

81.99192.3248 X X

81.99192.3250 X

81.99192.3253 X X

81.99192.3260 X

81.99192.3267 X X X X X X X

81.99192.3276 replaced by

81.99192.3748

81.99192.3293 X X X X X X X

06S -

1580

Model

06S -

1581

X X X X X X

Model

89S -

0161

Model

89S -

0162

Model

26X -

0150

Model

28X -

0006

Model

30X -

0273

Intarder 81.99192.3295 X X X X

Seat heating, driver

Customer-specic control module (KSM)

Preparation, transverse dif ferential lock, rear axle (2-axle vehicle)

Fuel lter heater

Fuel lter heater , Separ

V oltage transformer , 12V

Headlight beam regulator 81.99192.3314 X X X X X X X

Engine brake, automatic, of f

ST AR T/ST OP device on engine

Pritarder/Intarder , automatic, of f

Bunk light, bottom 81.99192.3349 X X X X X X X

Storage locker lighting, top (left, middle)

81.99192.3298 X X

81.99192.3300 X X X X X X

81.99192.3303 X X X

81.99192.3304 X X X X X X X

81.99192.3305 X X X X X X

81.99192.3313 X X X X X X

81.99192.3316 X X X

81.99192.3317 X X X X X X X

81.99192.3337 X X X X

81.99192.3350 X X X X

Storage locker lighting, top (left, middle, right)

Central lubrication system

Fog lamps/additional high beam headlights and cornering light

Sockets in cab, 12V and 24V

Preparation, central lubrication system

81.99192.3351 X X X

81.99192.3352 X X X X

81.99192.3366 X X X X X

81.99192.3367 X X X X X X

81.99192.3379 X X

K100 2nd edition 21

INTRODUCTION

Model

Name Item no.:

Storage locker lighting, rear left

Storage locker lighting, rear right

T able of contents

I-CAN roof (standard)

Interior lights with ambient light

T opline radio 81.99192.3490 X

Multifunctional steering wheel

Electric cab tilt mechanism 81.99192.3617 X X

EDC7 Euro 3 D20...

EDC7 Common Rail Euro 3 D2676 LF , E-EGR

Gearbox / manual gearbox

81.99192.3395 X X X X X X X

81.99192.3396 X X X X X X X

81.99192.3400 X X X X X X X

81.99192.3405 X X X X X X X

81.99192.3461 X X X

81.99192.3501 X X

81.99192.3624 X X X X

81.99192.3625 X X X

81.99192.3748 X

06S -

1580

Model

06S -

1581

Model

89S -

0161

Model

89S -

0162

Model

26X -

0150

Model

28X -

0006

Model

30X -

0273

22 K100 2nd edition

EXPLANA T OR Y NOTES T O THE WIRING DIAGRAMS

INTRODUCTION

1 Electrical component designation

(example: diode V100 on the central electrical system, number 53)

2 Installation position on the front of the

central electrical system (here: stamped number 53)

3 Plug connection on the rear of the 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 dif ferent from 1

Note: For cable number or cable name, see MAN-cats ®.

K100 2nd edition 23

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)

7 Plug connection (example: 1-pin plug

connection X104)

8 Installation location of the component

(see: identications of installation positions)

9 Current path (numbered from 1 to 55/60

on each diagram)

INTRODUCTION

Installation positions for location identiers

Installation positions for left-hand-drive vehicles (TGS/TGX)

(A) Rear of vehicle (B1) Engine (B2) Gearbox

(C) Front of vehicle (C1) Bumper (C2) Entrance, right (C3) Entrance, left (E6) Area of central electrical system (E7) Control unit plug-in modules (E8) Back wall of cab

(F) Instrument panel (F1) Mid-section (F2) Steering column / steering wheel (F3) Pedals (F4) Front wall inside left (F5) Front wall inside right

24 K100 2nd edition

(F6) Driver ’ s seat (F7) Co-driver ’ s seat (F8) Shift console

(G) Battery box (H1) B-pillar , driver ’ s side (H2) A-pillar , driver ’ s side

(J1) B-pillar , co-driver's side (J2) A-pillar , co-driver ’ s side

(L) Ceiling/roof

(N) Front axle

(P) Rear axle (R1) Front frame sections (R2) Rear frame section (S1) Door , left (S2) Door , right

SERIES ST ANDARD WIRING DIAGRAM

K100 2nd edition 25

WIRING DIAGRAM NO. 81.99192.3079

A = V oltage supply , starting system sheet 1 of 22

Date: 09.2007

Legend

A 100 Central electrical system

A302 Central computer 2 A403 V ehicle management computer A435 Control unit, EDC

F 354 Main fuse (terminal 30-1) F355 Main fuse (terminal 30-2)

F399 Fuse, alternator (terminal 15) G 100 Battery 1 G101 Battery 2 G102 Alternator 1

K 171 Relay , consumers (terminal 15)

M 100 Starter Q 101 Steering lock

X 100 Ground connection, engine

X669 Plug conn., starter interlock

X1364 Jumper , central electrical system (central on-board computer) 90/1-90/2 X1365 Jumper , central electrical system (central on-board computer) 90/2-91 X1541 Plug conn., potential bushing + X1551 Plug conn., engine/EDC/gearbox II X1913 Jumper , line 30076 (motor power box) X1966 Plug conn., ignition lock X2549 Plug conn., IMR (starter) X4829 Plug conn., ignition lock (terminal R)

SERIES ST ANDARD WIRING DIAGRAM

K100 2nd edition 26

A = V oltage supply , starting system sheet 1 of 22

SERIES ST ANDARD WIRING DIAGRAM

K100 2nd edition 27

WIRING DIAGRAM NO. 81.99192.3079

A = On-board computer voltage supply / B = EBS voltage supply / C = V ehicle management computer voltage supply sheet 2 of 22

Date: 03.2005

Legend

A 100 Central electrical system

A302 Central computer 2 A403 V ehicle management computer

F 160 Fuse, EBS (ABS), trailer voltage supply

F161 Fuse, EBS (ABS), pressure control valve voltage supply

F162 Fuse, EBS (ABS), control

F243 Fuse, central on-board computer continuous positive

F244 Fuse, central on-board computer (terminal 30-1)

F245 Fuse, central on-board computer (terminal 30-2)

F246 Fuse, central on-board computer (terminal 15)

F371 V oltage supply , vehicle management computer (terminal 30)

F372 V oltage supply , vehicle management computer (terminal 15)

F400 Fuse, steering lock

F522 Fuse, line 30000

F523 Fuse, line 30000

X 1064 Jumper on central electrical system, item 37 (pin1-2) X1557 Plug conn., frame, left X1644 Earthing point, cab, next to central electrical system X4643 Potential distributor , line 59104

——– —————————————————————–

1 EBS

SERIES ST ANDARD WIRING DIAGRAM

K100 2nd edition 28

+ 206 hidden pages