Adaptive Cruise Control (ACC) [PDF]

Zitiervorschau

Electrical system Adaptive Cruise Control (ACC)

Editorial deadline 07/2010

81.99298-6662 MAN Truck & Bus AG Dachauer Str. 667 80995 MÜNCHEN oder Postfach 50 06 20 80976 MÜNCHEN

System description 2nd edition T 39 Systembeschreibung T 39, 2. Ausgabe Elektrische Anlage Abstandsgeregelte Fahrgeschwindigkeitsregelung (ACC, Adaptive Cruise Control) - Englisch Printed in Germany

System description T 39 2nd edition

Electrical system Adaptive Cruise Control (ACC)

81.99298-6662

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PREFACE/PUBLICATION DATA PREFACE This repair manual is intended to provide assistance in performing repairs correctly on vehicles and units. The technical details were correct at the time of going to press. This publication assumes that persons who use it possess the requisite technical knowledge in handling vehicles and units. Pictures and the corresponding descriptions are typical one-time representations; they do not always correspond to the unit or peripherals in question, but this does not necessarily mean they are incorrect. In such cases, plan and carry out the repair work in accordance with the sense of the instructions. Repair work on complex add-on units should be entrusted to our customer service or to the customer service of the manufacturing company. These units are mentioned specically in the text. Important instructions concerning technical safety and the safety of personnel are specically highlighted, as indicated below. CAUTION Type and source of danger Refers to working and operating procedures which must be followed in order to avoid exposing people to risk. WARNING Type and source of danger Refers to working and operating procedures which must be followed in order to avoid material damage or destruction. Note An explanatory note which is useful for understanding the working or operating procedure to be performed. Comply with general safety regulations when performing any repair work. Yours faithfully, MAN Truck & Bus AG

PUBLICATION DATA We reserve the right to make modications in the course of further development. © 2010 MAN Truck & Bus AG Reprinting, copying or translation, even of extracts, is not permitted without the written approval of MAN Truck & Bus AG. All rights under the copyright law are strictly reserved by MAN Truck & Bus AG. If any changes are made without the written approval of MAN Truck & Bus AG then MAN Truck & Bus AG shall not be liable for any warranty or guarantee claims arising from damage and defects attributable to the unauthorised modication. Furthermore, MAN Truck & Bus AG shall not be liable for any damage resulting from the unapproved modication. Editorial Department: SAWET-Y, OB/WT, 07/2010 Typesetting: SAWET-Y Pressure: MAN-Werksdruckerei (on-site printing works)

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TABLE OF CONTENTS Content

Chapter/Page

Index

5

Abbreviations

7

Introduction Safety instructions ....................................................................................................... 13 Type overview ............................................................................................................ 20 Operating instructions for circuit diagrams .......................................................................... 22 Device description System description ...................................................................................................... 26 General ................................................................................................................ 26 CAN data bus system structure ................................................................................... 27 Functional description .................................................................................................. 32 ACC system structure without ESP – old version (TGA) ..................................................... 32 ACC system structure without ESP – old version (TGS/TGX) .............................................. 33 ACC system structure with ESP – old version (TGA) ......................................................... 34 ACC system structure with ESP – old version (TGS/TGX) .................................................. 35 ACC system structure with ESP – old version (P11/P12/P14/P15/P16) ................................... 36 ACC system structure with/without ESP – new version (TGS/TGX) ....................................... 37 ACC system structure with ESP – new version (P11/P12/P14/P15/P16) ................................. 38 ACC control unit (A479) ............................................................................................ 39 Yaw rate sensor (B476) ............................................................................................ 42 ACC distance sensor (B574) ...................................................................................... 49 Modular voltage converter (T119) ................................................................................ 54 ACC distance button (S550) ....................................................................................... 57 Cruise control/road speed limiter switch (S284) ............................................................... 60 Continuous brake switch (S479) .................................................................................. 62 Stalk switch, cruise control/gearbox (A429) .................................................................... 64 Operation of the ACC system ..................................................................................... 66 Calibrating the ACC distance sensor (B574) ................................................................... 69 Calibrating the ACC distance sensor with HD20+LC30 (TGA) .............................................. 73 Calibrating the ACC distance sensor with HD30+LC40 (TGA/TGS/TGX) ................................ 81 Description of components ............................................................................................ 92 ACC control unit (A479) ............................................................................................ 92 Yaw rate sensor (B476) ............................................................................................ 93 ACC distance sensor (B574) ...................................................................................... 96 Modular voltage converter (T119) ................................................................................ 98 ACC distance button (S550) ....................................................................................... 99 Stalk switch, cruise control/gearbox (A429) .................................................................. 101 Multi-function steering wheel (A943) ........................................................................... 102 Diagnostics ............................................................................................................. 103 General .............................................................................................................. 103 SPN – diagnostic code description ............................................................................. 120 Test step list ........................................................................................................ 143 Additional circuit diagrams Brief overviews ......................................................................................................... Brief overview, ACC with ESP – old version (TGA) ......................................................... Brief overview, ACC without ESP – old version (TGA) ..................................................... Brief overview, ACC with ESP – old version (TGS/TGX) ................................................... Brief overview, ACC without ESP – old version (TGS/TGX) ............................................... Brief overview, ACC with or without ESP – new version (TGS/TGX) .................................... Brief overview, ACC with ESP – old version (P11/P12/P14/P15/P16) ................................... Brief overview, ACC with ESP – new version (P11/P12/P14/P15/P16) ................................. T 39 2nd edition

159 160 162 164 166 168 170 172 3

INDEX Catchword

Page

A ACC control unit (A479) Components ............................................................................................................................................. 92 Function.................................................................................................................................................... 39 ACC distance button (S550) Components ............................................................................................................................................. 99 Function.................................................................................................................................................... 57 ACC distance sensor (B574) Components ............................................................................................................................................. 96 Function.................................................................................................................................................... 49 ACC distance sensor 81.27610-0013 and 81.27610-0024 – old version; TRW Automotive Electronics ...... 49 ACC distance sensor 81.27610-0023 – new version; TRW Automotive Electronics..................................... 51 ACC system structure with ESP – new version (P11/P12/P14/P15/P16)...................................................... 38 ACC system structure with ESP – old version (P11/P12/P14/P15/P16) ....................................................... 36 ACC system structure with ESP – old version (TGA).................................................................................... 34 ACC system structure with ESP – old version (TGS/TGX) ........................................................................... 35 ACC system structure with/without ESP – new version (TGS/TGX) ............................................................. 37 ACC system structure without ESP – old version (TGA)............................................................................... 32 ACC system structure without ESP – old version (TGS/TGX) ...................................................................... 33 B Break box .................................................................................................................................................... 116 Bus/coach (P01 - P99) type overview ........................................................................................................... 22 C Calibrating the ACC distance sensor (B574)................................................................................................. 69 Calibrating the ACC distance sensor with HD20+LC30 (TGA) ..................................................................... 73 Calibrating the ACC distance sensor with HD40+LC40 (TGA/TGS/TGX)..................................................... 81 CAN data bus system structure..................................................................................................................... 27 Continuous brake switch (S479).................................................................................................................... 62 Cruise control/road speed limiter switch (S284) ............................................................................................ 60 D Diagnostic socket HD-OBD (X200) ............................................................................................................. 106 Diagnostic socket, 12-pin (X200)................................................................................................................. 105 F Fluke ScopeMeter 123 ................................................................................................................................ 118 G General Diagnostics............................................................................................................................................. 103 System ..................................................................................................................................................... 26 I Installation locations for location designations .............................................................................................. 23 Installation locations of the diagnostic socket (X200), TGA ........................................................................ 107 Interfaces to other systems ........................................................................................................................... 26 L Limits of the ACC system .............................................................................................................................. 26 M Main functions of the diagnostics ................................................................................................................ 109 Malfunction indicators.................................................................................................................................. 109 Modular voltage converter (T119).................................................................................................................. 54 Components ............................................................................................................................................. 98 Monitoring with MAN-cats® II:........................................................................................................................ 90 Multi-function measuring device – multimeter ............................................................................................. 117 Multi-function steering wheel (A943) T 39 2nd edition

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INDEX Components ........................................................................................................................................... 102 O Operating instructions for circuit diagrams .................................................................................................... 22 Operation of the ACC system........................................................................................................................ 66 P Performing calibration with MAN-cats® II....................................................................................................... 76 R Resistance measurement............................................................................................................................ 152 S Safety instructions ......................................................................................................................................... 13 General..................................................................................................................................................... 13 SPN – diagnostic code description.............................................................................................................. 120 Stalk switch, cruise control/gearbox (A429) Components ........................................................................................................................................... 101 Function.................................................................................................................................................... 64 Status display, FMI (Failure Mode Identication)......................................................................................... 111 Structure of the fault texts in the diagnostic message ................................................................................. 112 System structure of communication lines .................................................................................................... 103 T Test step list................................................................................................................................................. 143 Test step list for ACC with multi-function steering wheel (A943) ................................................................. 152 Test step list for ACC without multi-function steering wheel (A943) ............................................................ 143 Troubleshooting program ............................................................................................................................ 118 Trucknology Generation A (H01 - H99) type overview .................................................................................. 20 Trucknology Generation S (01S - 99S, 01W - 99W) type overview .............................................................. 21 Trucknology Generation X (01X - 99X) type overview .................................................................................. 21 V Voltage measurement.................................................................................................................................. 153 Y Yaw rate sensor (B476) Components ............................................................................................................................................. 93 Function.................................................................................................................................................... 42 Yaw rate sensor 81.25937-0050; Knorr brake............................................................................................... 42 Yaw rate sensor 81.25937-0051; Knorr brake............................................................................................... 44 Yaw rate sensor 85.25808-6001; Wabco....................................................................................................... 47

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LIST OF ABBREVIATIONS Abbreviations A a ABE ABS ABV AC ACC ACK ADC ADR AGB AGND AGR AHK AHV ALB AMA AMR ANH AS ASD ASM ASR ASV ATC ATF AU AV AVS

Acceleration General operating permit Anti-lock braking system Automatic anti-lock braking system Air-conditioning system Adaptive Cruise Control Acknowledge Analogue-digital converter European Agreement concerning the International Carriage of Dangerous Goods by Road Automatic speed limiter Analogue ground Exhaust gas recirculation (EGR) Trailer coupling Trailer brake valve Automatic load-dependent brake force regulation Antenna mast system Anisotropic magneto-resistive Trailer/semitrailer Automatic gearbox Trailer socket Trailer control module Anti-spin regulator Trailer control valve Automatic temperature control Automatic transmission uid (automatic gearbox oil) Exhaust-gas inspection Exhaust valve Automatic preselection system

B BA BBA BBV BITE BKR BUGH BV BVA BVS BVV BW BWG BZ

Operator's Manual Service brake system Service brake valve Built-in test Brake force regulator Front heater Backup valve Brake lining wear display Brake lining wear sensor Brake lining wear sensor – supply German Army Braking value sensor Brake cylinder(s)

C CAN CAN-H CAN-L CATS CBU CDC CCVS CKD CNG CPU CRT CRC CS

Controller Area Network (data bus system with bit-serial transfer) CAN-High data line CAN-Low data line Computer-assisted testing and diagnostic system Central brake unit Continuous damping control Cruise control vehicle speed Completely knocked down Compressed natural gas Central processing unit (central computer) Continuously regenerating trap (exhaust silencer, oxidising catalytic converter, diesel particulate lter) Cyclic redundancy check Comfort shift T 39 2nd edition

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LIST OF ABBREVIATIONS D DAHL DBR DCU DF DFÜ DIA DIAG DIAG MUX DIAK DIAL DIAR DIN DKE DKH DKL DKR DKV DLB DM DNR DPF DRM DRS DS DSV DTC DTCO DV DWA DZG DZM E EBS ECAM ECAS ECE ECU EDC EDC S EDM EDR EEC EEPROM EFR EFS EHAB ELAB ELF EMS EMV EOL EP ER ESAC ESP ESR EST EV 8

Roof ventilator Continuous brake relay Dosing control unit (AdBlue metering) Speed sensor Data communication Diagnostics and information display Complete vehicle diagnostics Complete vehicle diagnostics – multiplex central computer (bus/coach only) Diagnostics, communication line Diagnostics, L line (response line) Diagnostics, further response German Institute for Standardization Throttle valve increase (ASR regulation) Roof duct heating Roof-mounted air inlets Throttle valve reduction (reduction request from ASR to EDC/EMS) Throttle valve setpoint (load sensor signal from EDC/EMS pedal-travel sensor) Compressed-air brake system Diagnostic message Drive Neutral Reverse (multi-function switch for automatic) Diesel particulate lter Axle modulator Yaw rate sensor Pressure sensor Pressure control valve Diagnostic trouble code (OBD diagnostic code) Digital tachograph Throttle valve Anti-theft warning system Speed sensor Rev counter

Electronic brake system Electronically controlled air management Electronically controlled air suspension Emergency shut-off according to ECE 36 Electronic control unit Electronic diesel control Electronic diesel control slave Electronic diesel consumption measuring system Maximum-speed governor Electronic engine controller Electrically Erasable Programmable Read Only Memory Electronic running gear control Electric driver's seat Electro-hydraulic shut-off device Electrical shut-off device Electronically controlled air suspension (ECAS) Electronic engine control Electromagnetic compatibility (EMC) End of line (programming) Injection pump Engine retarder (engine brake) Electronic shock absorber control Electronic stability program Electronic roller sunblind Electronic control unit Inlet valve T 39

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LIST OF ABBREVIATIONS EVB

Exhaust valve brake

F FAP FAQ FBA FBM FDR FDF FFR FGB FGR FHS FIN FM FMI FMS FMR FOC FSCH FSG FSH FTW FUNK FZA FZNR

Driver's workplace Frequently asked questions Parking brake system Footbrake module Ride dynamics control Vehicle data le Vehicle management computer Road speed limiter Cruise control Cab Vehicle identier (17 digits) Vehicle management Failure mode identication (fault type) Fleet management standard (manufacturer-independent telematics standard) Vehicle engine control Front omnibus chassis (bus/coach chassis with front-mounted engine) Windscreen heating Tracks for difcult terrain Window mirror heater Driver's partition Radio installation Destination system Vehicle number (7-digits)

G GDK GEN GET GGVS GND GP GS GV

Regulated diesel catalytic converter Alternator Gearbox European Agreement concerning the International Carriage of Dangerous Goods by Road (ADR) Ground Gearbox planetary group (range-change group) Gearbox control Gearbox splitter box

H RA HBA HD-OBD HDS HGB HGS HLUE HOC HSS HST HU HYD HYDRIVE HYDRO HVA Hz HZA HZG

Rear axle (RA) Secondary braking system Heavy duty on-board diagnosis Urea metering system Maximum speed limitation Hydraulic gearshift Hydrostatic fan Rear bus/coach chassis (bus/coach chassis with rear engine) Highside switch Main control panel Main inspection Hydronic auxiliary heater Hydrostatic front-wheel drive control unit MAN HydroDrive Hydrostatic front-axle drive Hertz (change/period per sec) Stop signal system Auxiliary speed sensor

I IBEL IBIS IC ID

Interior lighting Integrated on-board information system Integrated circuit Identication T 39 2nd edition

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LIST OF ABBREVIATIONS IMR INA INST IR IRM ISO IWZ

Integrated mechanical relay (start control) Information display (e.g. check lamp) Combined instrument Individual regulation (ABS) Individual regulation modied (ABS) International Organization for Standardization Incremental angle and time measurement system

K KBZ KFH KITAS KLI KNEEL KSM KSW KWP

Combination brake cylinder Fuel lter heating Kienzle intelligent tachograph sensor Air-conditioning system Kneeling Customer-specic control module (control unit for external data exchange) Customer special request Key word protocol (protocol for diagnostics with MAN-cats KWP 2000)

L LBH LCD LDA LDF LDS LED LF LGS LL LLA LLR LNA LNG LOE LPG LSVA LWR LWS

Air tank Liquid crystal display Charging pressure-dependent full-load stop Charging pressure sensor Air suspension damper system Light emitting diode Air suspension Lane Guard System Idling speed Idling speed increase Idling speed control Steered trailing axle Liqueed natural gas Steering oil monitoring Liqueed petroleum gas Heavy vehicle fee (HVF) Headlight beam regulator Steering angle sensor

M M-TCO MAB MAN-cats MAR MDB MES ML MMI MOTB MP MR MSG MUX MV MZ

Modular EU tachograph Solenoid valve stop (engine shut-off via high-pressure solenoid valve in the injection pump) MAN-computer-assisted testing and diagnostic system Solenoid valve stop relay (redundant engine shut-off relay) Main control board Flow regulator Midline Man-machine interface Engine brake MP box (cable channel at engine block) Engine regulator – ASR EDC engine control unit Multiplex central computer (bus/coach only) Solenoid valve Diaphragm brake cylinder

N n NA NBF NES NFZ NLA

Speed Power take-off (PTO) Needle movement sensor New electronics structure Commercial vehicle Trailing axle (TA)

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LIST OF ABBREVIATIONS NSL NSW

Rear fog lamp Fog lights

O OBD OBDU OC OEAB OENF

On-board diagnosis On-board diagnostic unit (subsystem of the central on-board computer) Occurrence count (error frequency counter) Oil separator Oil top-up

P p P PBM P-Code PDF PLM PM-Kat PSC PSG PTM PTO PWG PWM

Pressure Powertrain (driveline) Pulse breadth modulation (pulse-width modulated signal, see also PWM) Powertrain code (powertrain/driveline diagnostic code) Diesel particulate lter Programmable logic module PM catalytic converter Pneumatic supply controller – replacement for ECAM Pump control unit (EDC) Power Train Manager (replacement for vehicle management computer) Power take-off Pedal-travel sensor Pulse width modulation (pulse-width-modulated signal, see also PBM)

R RA RAH RAM RAS RAS-EC RDRA RDS RET RET P RET S RKL RKS RLV RME ROM

Repair manual Cab heating Random Access Memory (volatile read/write memory) Rear axle steering (steered rear axle) Rear axle steering, electronically controlled (electronically controlled steered rear axle) Tyre pressure control system Radio Data System Retarder Primary retarder Secondary retarder Revolving beacon Tyre monitoring system – replaced by TPM Relay valve Rape methyl ester (biodiesel) Read-only memory

S SA SAE SAMT SB SBW-RA SCR sec SER SG SH SKD SL SML SPN STA SWR

Optional equipment Society of Automotive Engineers Semi-automatic mechanical transmission Service outlet Steer by wire rear axle (electronically controlled steered trailing axle) Selective Catalytic Reduction Second Standard Control unit (CU) Select high control (ABS) Semi knocked down Select low control (ABS) Side marker lights Suspect parameter number Engine start/STOP Headlight cleaning system

T t

Time T 39 2nd edition

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LIST OF ABBREVIATIONS TBM TC TCM TCO TCU TEPS TGA TGL TGM TKU TMC TPM TRS TSC TSU TUER

On-board telematics module Traction control (anti-spin regulator) Trailer control module Tachograph (MTCO, DTCO, TSU, etc.) Transmission control unit Twin electronic platform systems (bus/coach only) Trucknology Generation A Trucknology Generation Light Trucknology Generation Mid Technical customer document Trafc Message Channel Tyre pressure module Technical guideline for roads Torque speed control (brake torque) Tachograph simulating unit (for vehicles without MTCO/DTCO) Door control

U UBat UDF UDS

Battery voltage Conversion data le Accident data memory

V v VA VDF VG VLA VSM

Speed Front axle (FA) Vehicle data le Transfer case or in accordance with defence equipment standards Leading axle (LA) Transfer case lock management

W WA WAB WaPu WLE WR WS WSK

Maintenance manual Water trap Coolant pump, intarder Swap body unit Warning relay Displacement sensor Converter-clutch unit

Z z ZBR ZBRO ZDR ZE ZFR ZR ZS ZUSH ZWS λ µ µC

Braking Central on-board computer Central on-board computer, bus/coach Intermediate speed control Central electrical system Additional vehicle computer Central computer Central lubrication system Auxiliary heater Time-based maintenance system Slip Coefcient of friction Microcontroller (microprocessor)

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INTRODUCTION

INTRODUCTION SAFETY INSTRUCTIONS General Only trained personnel are permitted to perform operating, maintenance or repair work on trucks and buses /coaches. The following sections include summaries of important regulations listed according to major topics. These must be observed, in order to avoid accidents which could lead to injury, damage and environmental pollution. They constitute only a short extract from the numerous accident prevention guidelines. Of course, all other safety regulations must be followed and the necessary measures must be taken. Additional references to danger are contained in the instructions at points where there is a potential danger. Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality, obtain immediate medical assistance from a doctor. This is particularly important if the accident involves skin contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes, crushing limbs, etc. 1. Regulations for preventing accidents leading to injury to personnel During inspection, adjustment and repair work – Secure units during their removal. – Support the frame when working on the air or spring suspension system. – Keep units, ladders, stairs, steps and the surrounding area free from oil and grease. – Do not use any tools that are not in perfect condition. – Only authorised technical personnel are entitled to perform inspection, adjustment and repair work. Working on the brake system – Please use a dust extraction device if dust is released during work on the brake system. – Perform visual, functional and effectiveness checks on the brake system after carrying out any work on it whatsoever. These safety inspection checks (SP) must be made in accordance with the relevant statutory regulations governing special brake inspections. – Use a suitable test system (e.g. MAN-cats) to check the function of the ABS/ASR systems. – Collect any brake uid that leaks out. – Brake uid is poisonous! Do not allow it to come into contact with food or open wounds. – Treat hydraulic uid/brake uid as hazardous waste! Comply with the safety regulations for preventing environmental pollution. Working on vehicles with a compressed natural gas (CNG) system – Vehicles with a defective compressed natural gas system may not be brought into the workshop. This also applies to vehicles whose engines cannot be switched off by automatic emptying of the supply lines. – When working on vehicles with a compressed natural gas system, set up a gas warning device above the vehicle roof and in the engine compartment above the pressure governor. Further gas warning devices must be carried by the persons working on the vehicle. – Smoking is not allowed in areas where work on vehicles with compressed natural gas systems is carried out. All sources of ignition must be removed from these areas. – Before carrying out welding, the gas tanks must be removed and the gas-carrying lines must be ushed with inert gas. – Gas tanks must not be subject to temperatures in excess of 60°C in painting and drying booths. If temperatures exceed this value, the gas tanks must be removed or degassed and ushed with inert gas (e.g. nitrogen). Furthermore, gas-carrying lines must be ushed with inert gas. Working on the compressed natural gas (CNG) system – Work on the compressed natural gas system may only be carried out by persons who have been specically trained to do so. – The working area for the compressed natural gas system must be equipped with an adequate ventilation system. The ventilation system must replace the air in the room with new air at least three times per hour. – After following the prescribed procedures to replace standard-t components of the compressed natural gas system, check the assembly points for leaks. Perform these checks using a leak indicator spray or a gas warning device. T 39

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INTRODUCTION Operating the engine – Only authorised personnel are permitted to start and operate an engine. – Do not get too close to the moving parts of a running engine and do not wear baggy clothing. Use an extractor system in enclosed spaces. – Risk of burning when working on engines at operating temperature. – Danger of scalding when opening the hot cooling circuit. Suspended loads – Persons may not stand or walk underneath suspended loads. – Only use suitable hoists that are in top condition technically. Please also make sure that the load suspension devices used have sufcient load capacity. Attachments and special bodies – Comply with the safety instructions and regulations issued by the body manufacturer in question if bodies or special bodies are tted. Working on high-pressure lines – Do not attempt to tighten, loosen or open pipes and hoses (e.g. in the lubrication circuit, coolant circuit and hydraulic oil circuit) whilst they are pressurised: Risk of injury from liquids escaping under pressure. Testing injection nozzles – Please wear the relevant protective equipment. – Keep all body parts away from the jet of fuel when checking the injection nozzles. – Do not breathe in fuel vapour, ensure sufcient ventilation. Work on the vehicle electrical system – Do not disconnect the batteries whilst the engine is running! – Always disconnect the batteries when working on vehicle electronics, central electrical system, alternators and starters. Disconnect the negative terminal rst when disconnecting the battery. Connect the positive terminal rst when connecting. – Use only matching test lines or test adapters to measure at plug connectors. – If you expect temperatures in excess of 80°C (e.g. in the dryer after painting), set the main battery switch to "OFF" and then remove the control units. – The frame is not intended for use as a ground return. If attachments are to be tted to the vehicle (e.g. a wheelchair lift), additional ground cables with an adequate cross-section must be routed as well. Otherwise the ground connection may be created along wire cables, cable harnesses, gearbox shafts, gears, etc. Severe damage could result. Important: battery gases are explosive! – Oxyhydrogen gas may form in enclosed battery boxes. Take particular care after long journeys and after charging the batteries with a battery charger. – When the batteries are disconnected, the gas may be ignited by sparks produced by continuously operating consumers, tachographs, etc. that cannot be switched off. Blow compressed air through the battery box before disconnecting the batteries. – Only tow-start a vehicle if the batteries are connected. Tow-start vehicles only if the check lamps light up brightly, but there is insufcient battery power to start the vehicle. Do not use a boost-charger to jump-start the vehicle! – Always disconnect the positive cable and ground cable before boost-charging and charging batteries! – Do not boost-charge lead gel and maintenance-free batteries. (not for "maintenance-free according to DIN") Maximum loading capacity is 10% of the stated capacity of each battery. Parallel connections increase capacity according to the number of batteries connected in parallel. – Risk of short-circuit if batteries have been incorrectly connected. – Do not place any metal objects (keys, pliers, etc.) on the batteries otherwise there may be a short-circuit at the terminals. Risk of short-circuit. – Disconnect the batteries and recharge them every 4 weeks if the vehicle is not in use over a prolonged period of time. Caution! Battery acid is poisonous and corrosive! – Wear suitable protective clothing (gloves) when handling batteries. Do not tip or tilt batteries as acid may emerge. Do not tip or tilt gel batteries either.

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INTRODUCTION – Only measure voltage with suitable measuring devices! The input resistance of a measuring device should be at least 10 MΩ. – Connect/disconnect the plug connectors of electrical control units only when the ignition is switched off. Electric welding – Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN item number 80.78010.0002) as described in the instructions accompanying the device. – If this device is not available, disconnect the batteries and rmly connect the positive cable to the ground cable in order to make a conductive connection. – The manually operated main battery switch is in the driving mode position. If an electronic main battery switch has been tted, bypass the “negative” at the power relay contacts (jumper cable > 1 mm2) and bypass the “positive” at the power relay load contacts. Also switch on numerous power consumers, such as: starter switch (ignition) in driving mode position, hazard warning system switch “on”, lighting switch in “low-beam headlights on” position, fan ventilation to “maximum”. The more consumers are switched on, the higher the protection. When welding is complete, rst switch off all consumers and remove all jumpered connections (reset to original condition) before connecting the batteries. – Always ground the welding equipment as close as possible to the welding area. Do not route the welding equipment cable parallel to the electrical cables in the vehicle. Work on plastic tubes – risk of damage and re – Plastic tubes must not be subject to mechanical or thermal load. Painting work – During painting work, electronic components may only be exposed to high temperatures (max. 95°C) for short periods; a period of up to approx. 2 hours is permissible at max. 85°C; disconnect the batteries. Do not paint the bolt connections of the high-pressure section of the injection system. Danger of ingress of dirt when repair work is carried out. Working with a tilted cab – Keep the tilting area in front of the cab clear. – Stay out of the area between the cab and the chassis while the cab is being tilted! Danger zone! – Always tilt the cab over the tipping point or secure the cab with a prop. Work on the air-conditioning system – Refrigerant uids and vapours represent a health hazard, avoid contact and protect eyes and hands. – Do not drain gaseous refrigerants in enclosed areas. – Never mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant. – Dispose of refrigerant according to instructions. Work on the airbag or belt pretensioner units – Work on airbags or belt pretensioner units must only be performed by personnel that can provide proof of a specialist course at the MAN Service Academy. – Mechanical loads, impacts, heating to over 140°C, electrical pulses and electrostatic discharge may trigger unwanted ignition of the airbag or belt pretensioner units. – Hot gases are released explosively when the airbag or belt pretensioner units are triggered. Airbag or belt pretensioner units that are not tted may be catapulted around uncontrollably. For this reason, there is a risk of injury for persons in or near the cab. – Risk of burning when touching the hot surfaces after the airbag has been triggered. – Do not open a triggered airbag or air cushion. – Do not touch a triggered airbag with a destroyed air cushion with your bare hands. Wear protective gloves made of nitrile rubber. – Before performing any work and inspections on the airbag or belt pretensioner units, or working on the vehicle where impacts are likely, it is necessary to switch off the ignition, remove the key from the ignition lock, disconnect the ground cable from the battery and disconnect the plug connector for the airbag and belt pretensioner power supply. – Fit the driver airbag restraint system, MAN item number 81.66900-6035, to the airbag steering wheel as instructed in the Operator's Manual. – Only perform inspections on airbag and belt pretensioner units with devices specically intended for this purpose. Do not use inspection lamps, voltmeters or resistance meters.

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INTRODUCTION – After having nished all work and inspections, switch off the ignition rst, then connect the plug connector(s) for the airbag and belt pretensioner and, as a last step, connect the battery. Please ensure there is no one in the cab when doing this. – Only place airbag units individually, with the impact cushion facing up. – Do not apply grease or cleaning agents to airbags and belt pretensioners. – Store and transport airbag and belt pretensioner units in their original packaging only. It is not permitted to transport them inside the passenger compartment. – Airbag and belt pretensioner units may only be stored in storage areas that can be locked, and up to a maximum of 200 kg. Working on the independent heater – It is necessary to switch off the heater unit and allow all hot components to cool down before beginning work. – Ensure that suitable collecting containers are available and that no sources of ignition are present when working on the fuel system. – Keep suitable re extinguishing equipment nearby and within easy reach! – The heater unit must not be operated in enclosed areas such as garages or workshops without an extractor system. 2. Guidelines for preventing damage and premature wear on units General – Units are only built for the purpose designated in the scope of delivery (according to their intended use), which is dened by the device manufacturer: Any other use is classied as not in accordance with the designated use. The manufacturer does not assume liability for any damage resulting from this. Any other use is carried out at user's risk only. – The intended use also includes compliance with the operating, maintenance and repair conditions dened by the manufacturer. – The unit must only be used,maintained and repaired by personnel who are acquainted with it and have been instructed about any potential danger. – The manufacturer does not assume any liability for damage resulting from unauthorised modications to the engine. – Manipulation of the injection and control system may also affect the performance and exhaust-gas values of the unit. Compliance with legal environmental regulations would then no longer be guaranteed. – Should faults occur during operation, the cause must be determined and rectied immediately. – Thoroughly clean the units prior to repair work and ensure that all openings where the ingress of dirt could cause functional or safety issues, are sealed. – Never run units dry, i.e. always make sure that they have been lled with lubricating oil before running them. – Never run engines that have not been lled with coolant beforehand. – Use a suitable information sign to clearly indicate units that are not ready to be operated. – Use service products only in accordance with MAN service product recommendations; otherwise the manufacturer's warranty is rendered void. You can nd approved products on the Internet at: http://www.man-mn.com/ > Products & Solutions > E-Business. – Comply with the specied service intervals. – Do not ll engine/gearbox oil above the maximum level mark. Do not exceed the maximum permitted operational tilt. – The special measures described in MAN Works Standard M 3069 Part 3 are necessary if buses/coaches or trucks are to be withdrawn from service or held in storage for longer than 3 months. 3. Limited liability for spare parts and accessories General Please use only accessories approved by MAN Truck & Bus AG and MAN genuine parts for your MAN vehicle. MAN Truck & Bus AG does not assume any liability for any other products. 4. Regulations for avoiding injury and environmental contamination Health protection precautions Avoid extended, excessive or repeated skin contact with service products, process materials, diluting agents and solvents. Protect your skin using a suitable skin protection agent or protective gloves. Do not use any

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INTRODUCTION service products, process materials, diluting agents or solvents to clean your skin. Apply a moisturising skin cream after cleaning your skin. Service products and process materials Do not use any containers intended for food or beverages to drain and store service products or process materials. Please observe instructions issued by the relevant local authority on the disposal of service products and process materials. Coolant Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority when disposing of used coolant (mixture of antifreeze and water). Cleaning the cooling circuit Do not pour cleaning uids and rinsing water down the drain if this practice is restricted by specic local regulations. However, the cleaning uid and rinsing water must, in all cases, be passed through an oil separator with a sludge trap. Cleaning the lter insert When blowing compressed air through the lter insert, make sure the lter dust is collected by an extractor system, or is blown into a dust collection bag. Otherwise, use a respiratory protection mask. Wear rubber gloves or use a skin barrier hand cream when washing out the insert, because cleaning agents have aggressive grease-dissolving characteristics. Engine/gearbox oil, lter cartridges, inserts and box-type lters, desiccant cartridges Filter inserts, cartridges and box-type lters (oil and fuel lters, desiccant cartridges for the air dryer) are classied as hazardous waste materials. Please observe instructions issued by the relevant local authority on the disposal of uids and process materials mentioned above. Used engine/gearbox oil Lengthy or repeated skin contact with any type of engine/gearbox oil removes grease from the skin. This can cause dry skin, irritation or skin inammation. In addition to these hazards, used engine oil contains hazardous materials which can cause dangerous skin diseases. It is particularly important to wear gloves during an oil change. Dealing with AdBlue® AdBlue® is a synthetically produced 32.5% urea water solution used as an NOx reduction additive for diesel engines with an SCR catalytic converter. AdBlue® is not a hazardous material. However, it disintegrates to ammonium hydroxide and carbon dioxide during storage. For this reason, AdBlue® is classied in Germany as water-polluting (WGK 1, water pollution class 1) and must not come in contact with waste water or seep into the ground. Ensure good ventilation of the work place when working on the AdBlue® system and do not eat, drink or smoke. Avoid skin and eye contact with AdBlue®, thoroughly wash your hands and apply skin protection agent before taking breaks or nishing work. In the event of skin contact with AdBlue®, rinse skin with water and a skin cleaning agent and remove any soiled clothing immediately. Please seek medical advice in the event of skin irritation. In the event of eye contact with AdBlue®, rinse eyes with water or eye rinsing solution for a minimum of 10 minutes while keeping them open; remove contact lenses beforehand and seek medical advice if the complaint persists. Immediately call for medical advice if AdBlue® has been swallowed. Store AdBlue® containers in uid-tight collecting chambers at storage temperatures of no more than 25°C. Absorb leaked or spilt AdBlue® with binding agents and dispose of this according to the regulations. 5. Information for working on the Common Rail system General – Fuel jets can cut through the skin. There is a re risk due to atomisation of the fuel. – Never undo the bolt connections on the high fuel pressure side of the Common Rail system when the engine is running (high-pressure line from the high-pressure pump to the rail, at the rail and on the cylinder head to the fuel injector). When the engine is running, the lines are under a constant fuel pressure in excess of 1800 bar. Wait at least one minute before opening the bolt connections until the pressure has dropped. Check pressure reduction on the rail with MAN-cats, if applicable. – Do not remain in the vicinity of the engine when it is running. – Do not touch live parts at the electrical connection of the fuel injectors when the engine is running. – Any change to the original wiring may lead to the limit values of the heart pacemaker regulations being exceeded, e.g. untwisted fuel injector wiring or insertion of a break box (terminal tester).

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INTRODUCTION – Vehicle operators and persons with heart pacemakers are not at risk from systems with MAN Common Rail engines in approved operation. – Fuel jets can cut through the skin. There is a re risk due to atomisation of the fuel. – Never undo bolt connections on the high fuel pressure side of the Common Rail system when the engine is running (fuel injection line from the high pressure pump to the rail, at the rail and on the cylinder head to the fuel injector). – Do not remain in the vicinity of the engine when it is running. – When the engine is running, the lines are under a constant fuel pressure in excess of 1800 bar. – Wait for at least one minute before undoing bolt connections to allow the pressure to drop. – If necessary, check that the pressure has dropped in the rail with MAN-cats. – Do not touch live parts at the electrical connection of the fuel injectors when the engine is running. Information for people with pacemakers – Any change in the original engine cabling may lead to the limit values of the heart pacemaker regulations being exceeded, e.g. untwisted fuel injector cabling or insertion of a break box (terminal tester). – There is no danger to the driver or any passengers with pacemakers, in approved operation. – Vehicle operators with heart pacemakers are not at risk from systems with MAN Common Rail engines, in approved operation. – The product in original condition complies with all the currently known limit values for heart pacemakers. Risk of damage due to ingress of dirt – The components of the diesel fuel-injection system consist of high-precision parts that are subjected to extreme loads. Due to the highly precise nature of this technology, all work on the fuel system requires the highest possible degree of cleanliness. – Even dirt particles above 0.2 mm in size can cause component failure. Before starting work on the clean side – Clean the engine and engine compartment while the fuel system is still closed off; when doing so, do not use a powerful jet to clean the electrical components. – Drive the vehicle into a clean area of the workshop in which no work is performed that could swirl up dust (grinding or welding work, brake repairs, brake and power testing, etc.). – Avoid air movements (possible swirling up of dust through starting of engines, workshop ventilation/heating, draughts, etc.). – The area of the fuel system that is still closed must be cleaned and dried by means of compressed air. – Remove loose dirt particles such as paint akes and insulating material with a suitable suction device (industrial vacuum cleaner). – Cover areas of the engine compartment from which dirt particles could become detached, e.g. tilted cab, engine compartment of bus engines, with new and clean foil covering sheets. – Before starting disassembly, wash your hands and put on a clean working overall. After opening the clean side – It is not permitted to use compressed air for cleaning. – Loose dirt must be removed during assembly work using a suitable suction device (industrial vacuum cleaner). – Only lint-free cleaning cloths are allowed to be used on the fuel system. – Clean tools and working equipment before starting work. – Only tools that are not damaged (e.g. cracked chromium plating) must be used. – Materials such as cloths, cardboard or wood must not be used when removing and tting components, as particles and bres may become detached from such materials. – If paint akes should be produced when undoing connections (e.g. due to painting over the connections), these must be carefully removed before the bolt connection is nally undone. – The connection opening of all removed parts of the clean-side fuel system must be closed off immediately with suitable caps. – These sealing parts must remain packaged dust-tight until use and must be disposed of after being used once. – The components must then be stored carefully in a clean, closed container. – Cleaning or test uids that have already been used must not be used for these components. – New parts must only be taken out of the original packaging immediately before use. – Work on removed components must be performed only at a work place equipped for this purpose. – If removed parts are shipped, always use the original packaging of the new part. When performing the work on bus engines, it is essential that the following measures are also observed:

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INTRODUCTION Risk of damage due to ingress of dirt – Before opening the clean-side fuel system: Clean the engine areas around the pressure sockets, fuel-injection lines, rail and cylinder head cover with compressed air. – Remove the cylinder head cover and then clean the engine areas around the pressure sockets, fuel-injection lines and rail once again. – First only loosen the pressure pipe sockets: Loosen the pressure pipe socket union nuts and unscrew four turns. Lift the pressure pipe sockets with a special tool. Reason: only fully remove the pressure pipe sockets when the fuel injectors have already been dismantled so that no dirt can fall into the fuel injectors from above. – Remove the fuel injectors. – After removal, rinse out the injectors with a cleaning uid, making sure that the high-pressure connection hole is facing downwards. – Remove the pressure pipe sockets; to do this, unscrew the pressure pipe socket union nut. – Clean the injector bore in the cylinder head. 6. Limp-home program for units with electronic control units General information The units have an electronic control system that monitors itself (self-diagnostics) and the unit. As soon as there is a malfunction, the malfunction is evaluated and one of the following measures is initiated: – Output of a fault message with a diagnostic memory entry. – Changeover to suitable, yet limited operation. Have malfunctions rectied by MAN Service immediately. – The diagnostic memory entry is output directly in conjunction with MAN-cats. 7. Assembly information Assembling pipes – Pipes must not be mechanically deformed during assembly work; risk of fracture. Mounting gaskets – Only use MAN genuine gaskets – Make sure that the areas to be sealed are undamaged and clean. – Do not use adhesive agents or sealing agents. If necessary, to facilitate installation, use a little grease to stick the seal to the part to be mounted. – Tighten the bolts evenly to the specied tightening torque. Mounting O-rings – Only use MAN genuine O-rings. – Make sure that the areas to be sealed are undamaged and clean. Engine overhaul – The engine's service life is inuenced by very different factors. For this reason, it is not possible to state specic operating hours or mileage values for general overhauls. – We are of the opinion that opening an engine or performing a general overhaul is not required, as long as the engine has good compression values and the following operating values do not deviate considerably from those determined at start-up. – Charging pressure – Exhaust gas temperature – Coolant and lubricating oil temperatures – Oil pressure and oil consumption – Smoke behaviour The following criteria have considerable inuence on the engine's service life: – Correct performance setting according to deployment – Correct installation – Approval of the installation by authorised personnel – Regular maintenance according to the maintenance record

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INTRODUCTION TYPE OVERVIEW The system description T 39 (2nd) Adaptive Cruise Control (ACC) is used in the following vehicles. Note: No claims are made regarding completeness of this list. Trucknology Generation A (H01 - H99) Type Model designation

Type Model designation

H01 TGA 18.D28 4X2 BLS-TS

H44

TGA 24.D28 6X2-2, 6X2-4 LL-U

H02 TGA 18.D28 4X2 BB

H45

TGA 24.D20 6X2-2, 6X2-4 LL-U

H03 TGA 18.D20 4X2 BB

H46

TGA 41.D28 8X4 BB-WW

H05 TGA 18.D28 4X2 BL

H48

TGA 32.D28 8X4 BB

H06 TGA 18.D20 4X2 BL

H49

TGA 32.D20 8X4 BB

H07 ECT 18.ISM 4X2 BL

H51

TGA 18.D28 4X4 BB

H08 TGA 18.D20 4X2 BLS-TS

H52

TGA 18.D20 4X4 BB

H09 TGA 18.D28 4X2 LL

H54

TGA 33.D28 6X6 BB-WW

H10 TGA 18.D20 4X2 LL

H55

TGA 26/33.D28 6X6 BB

H12 TGA 18.D28 4X2 LLS-U

H56

TGA 26/33.D20 6X6 BB

H13 TGA 18.D20 4X2 LLS-U

H57

TGA 40.D28 6X6 BB-WW

H14 TGA 18.D28 4X2 LL-U

H60

TGA 19.D28 4X2 BB-WW-SKD

H15 TGA 18.D20 4X2 LL-U

H61

TGA 18.D28 4X2 BL-WW-SKD

H16 TGA 26.D08 6X2-4 BL

H62

TGA 33.D28 6X4 BB-WW-SKD

H17 TGA 26.D28 6X2-2, 6X2-4 BL

H63

TGA 26.D28 6X4 BL-WW-SKD

H18 TGA 26.D20 6X2-2, 6X2-4 BL

H70

TGA 18.D28 4X4 BL

H19 TGA 26.D08 6X2-4 LL

H71

TGA 28.D28 6X2-4 BL/LL

H20 TGA 26.D28 6X2-2, 6X2-4 LL

H72

TGA 26/33.D28 6X6 BL

H21 TGA 26.D20 6X2-2, 6X2-4 LL

H73

TGA 35/41.D28 8X6 BB

H23 TGA 26.D28 6X2/2, 6X2/4 BL

H74

TGA 28.D20 6X2-4 BL

H24 TGA 26.D20 6X2/2, 6X2/4 BL

H75

TGA 28.D20 6X2-4 LL

H25 TGA 26/33.D28 6X4 BB

H76

TGA 35/41.D28 8X8 BB

H26 TGA 26/33.D20 6X4 BB

H80

TGA 18.D20 4X4 BL

H27 ECT 26.ISM 6X2-2, 6X2-4 BL

H82

TGA 26/33.D20 6X6 BL

H28 TGA 33.D28 6X4 BB-WW

H84

TGA 28.D20 6X4-4 BL

H29 TGA 26/33.D28 6X4 BL

H85

TGA 28.D20 6X2-2 LL

H30 TGA 26/33.D20 6X4 BL

H86

TGA 28.D28 6X2-2 BL

H31 ECT 26.ISM 6X2-2, 6X2-4 LL

H87

TGA 28.D28 6X2-2 LL

H32 ECT 26.ISM 6X2/2, 6X2/4 BL

H88

TGA 35.D28 8X2-4, 8X2-6 BL

H33 TGA 40.D28 6X4 BB-WW

H89

TGA 28.D20 6X2-2, BL

H36 TGA 35.D28 8X4 BB

H90

TGA 35.D20 8X2-4, 8X2-6 BL

H37 TGA 35.D20 8X4 BB

H93

TGA 35/41.D20 8X6 BB

H38 TGA 41.D28 8X4 BB

H94

TGA 41.D28 8X4/4 BB/BL (heavy-duty semitrailer tractor)

H39 TGA 41.D20 8X4 BB

H95

TGA 41.V10 8X4/4 BB/BL (heavy-duty semitrailer tractor)

H40 TGA 32/35.D28 8X4 BL

H96

TGA 35/41.D20 8X8 BB

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INTRODUCTION

H41 TGA 32/35.D20 8X4 BL

H99

TGA 28.D20 6X2-4 LL-LE

H43 TGA 19.D28 4X2 BBS-WW Trucknology Generation S (01S - 99S, 01W - 99W) Type Model designation

Type Model designation

03S

TGS 18.D20/D26 4X2 BB

39S

TGS 41.D20/D26 8X4 BB

06S

TGS 18.D20/D26 4X2 BL

41S

TGS 32/35.D20/D26 8X4 BL

08S

TGS 18.D20/D26 4X2 BL-TS

42S

TGS 26.D20/D26 6X4H/2, 6X4H/4 BL

10S

TGS 18.D20/D26 4X2 LL

45S

TGS 24.D20/D26 6X2-2 LL-U

13S

TGS 18.D20/D26 4X2 LLS-U

49S

TGS 32.D20/D26 8X4 BB

15S

TGS 18.D20/D26 4X2 LL-U

59S

TGS 35.D20/D26 8X6H BL

18S

TGS 26.D20/D26 6X2-2, 6X2-4 BL

70S

TGS 26/33.D20/26 6x6H BL

21S

TGS 26.D20/D26 6X2-2, 6X2-4 LL

73S

TGS 35.D20/D26 8X4H-6 BL

22S

TGS 18.D20/D26 4X4 H BL

74S

TGS 28.D20/D26 6X2-4 BL

24S

TGS 26.D20/D26 6X2/2, 6X2/4 BL

89S

TGS 28.D20/D26 6X2-2 BL

26S

TGS 26/33.D20/D26 6X4 BB

90S

TGS 35.D20/D26 8X2-4, 8X2-6 BL

30S

TGS 26/33.D20/D26 6X4 BL

92S

TGS 35.D20/D26 8X4-4 BL

35S

TGS 26.D20/D26 6X4H-2, 6X4H-4 BL

93S

TGS 35/41.D20/D26 8X6 BB

37S

TGS 35.D20/D26 8X4 BB

96S

TGS 35/41.D20/D26 8X8 BB

Type

Model designation

Type

Model designation

03W

TGS 19 4X2 BBS-WW

49W

TGS 32 8X4 BB-WW

06W

TGS 19 4X2 BLS-WW

71W

TGS 19 4X2 BBS-WW-CKD

18W

TGS 26 6X2-2, 6X2-4 BL-WW

72W

TGS 19 4X2 BLS-WW-CKD

19W

TGS 28 6X2-2 BL-WW

73W

TGS 28 6X2-2 BL-WW-CKD

26W

TGS 33 6X4 BB-WW

76W

TGS 33 6X4 BB-WW-CKD

30W

TGS 26/33 6X4 BLS-WW

78W

TGS 26 6X4 BL-WW-CKD

Trucknology Generation X (01X - 99X) Type Model designation

Type Model designation

05X

TGX 18.D20/D26 4X2 BLS

30X

TGX 26/33.D20/D26 6X4 BL

06X

TGX 18.D20/D26 4X2 BL

42X

TGX 26.D20/D26 6X4H/2, 6X4H/4 BL

10X

TGX 18.D20/D26 4X2 LL

45X

TGX 24.D20/D26 6X2-2 LL-U

13X

TGX 18.D20/D26 4X2 LLS-U

78X

TGX 18.V8 4X2 BLS

15X

TGX 18.D20/D26 4X2 LL-U

79X

TGX 33.V8 6X4 BL

18X

TGX 26.D20/D26 6X2-2, 6X2-4 BL

86X

TGX 41.D26 8X4/4 BBS

21X

TGX 26.D20/D26 6X2-2, 6X2-4 LL

87X

TGX 41.D26 8X4/4 BLS

22X

TGX 18.D20/D26 4X4H BL

89X

TGX 28.D20/D26 6X2-2 BL

24X

TGX 26.D20/D26 6X2/2, 6X2/4 BL

92X

TGX 35.D20/D26 8X4-4 BL

26X

TGX 26/33.D20/D26 6X4 BB

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INTRODUCTION Bus/coach (P01 - P99) Type

Model designation

Type

Model designation

P11

N 5217 SHD

P15

CITYLINER C

P12

N 5218 SHD

P16

CITYLINER L

P14

CITYLINER

OPERATING INSTRUCTIONS FOR CIRCUIT DIAGRAMS

(1) Electrical component designation (example – diode V100 on the central electrical system, position 53) (2) Installation location on the front of the central electrical system (here – embossed position number 53) (3) Plug connector on the back of the central electrical system (here – plug 78, connection 8)

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T 39

(4) Cable number, for colour cables: abbrev. of the colour description, cross-section stated only if not 1² (5) Cable designation, numbers in brackets are printed conductors of a printed circuit board (6) Line disconnection and line continuation with sheet number (sheet 2) and path number (path 4)

2nd edition

INTRODUCTION (7) Plug connector (example – single-pin plug connector X104) (8) Installation location of the component (see – identication of the installation locations)

(9) Current path (numbered from 1 up to 55/60 for each plan)

Installation locations for location designations Installation locations for left-hand drive vehicle (TG)

(A) (B1) (B2) (C) (C1) (C2) (C3) (E6) (E7) (E8) (F) (F1) (F2) (F3) (F4) (F5) (F6)

Rear Engine Gearbox Front Bumper Step unit, right Step unit, left Central electrical system area Control unit plug-in modules Cab rear wall Instrument panel Middle section Steering column/steering wheel Pedals Front wall, inside left Front wall, inside right Driver's seat

(F7) (F8) (G) (H1) (H2) (J1) (J2) (L) (N) (P) (R1) (R2) (S1) (S2)

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2nd edition

Co-driver's seat Gearshift console Battery box B-pillar, driver's side A-pillar, driver's side B-pillar, co-driver's side A-pillar, co-driver's side Ceiling/roof Front axle Rear axle Frame, front parts Frame, rear part Door, left Door, right

23

INTRODUCTION Installation locations for right-hand drive vehicle (TG)

(A) (B1) (B2) (C) (C1) (C2) (C3) (E6) (E7) (E8) (F) (F1) (F2) (F3) (F4) (F5) (F6) (F7) (F8) (G) (H1) (H2) (J1) 24

Rear Engine Gearbox Front Bumper Step unit, right Step unit, left Central electrical system area Control unit plug-in modules Cab rear wall Instrument panel Middle section Steering column/steering wheel Pedals Front wall, inside left Front wall, inside right Co-driver's seat Driver's seat Gearshift console Battery box B-pillar, co-driver's side A-pillar, co-driver's side B-pillar, driver's side

(J2) (L) (N) (P) (R1) (R2) (S1) (S2)

T 39

2nd edition

A-pillar, driver's side Ceiling/roof Front axle Rear axle (RA) Frame, front parts Frame, rear part Door, left Door, right

INTRODUCTION Installation locations for P11, P12, P14, P15, P16

(A) (B) (C) (D) (E) (E1) (F) (F1) (G) (H) (J) (K) (L) (N) (P)

Rear Engine, gearbox (EDC7 engine control) Front Main control panel Equipment compartment (battery box) Mounting plate 1 (auxiliary control panel) Instrument panel Instrument panel interface Battery box Left side of vehicle Right side of vehicle Middle of vehicle Ceiling Front axle Rear axle (RA)

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DEVICE DESCRIPTION

DEVICE DESCRIPTION SYSTEM DESCRIPTION General The Adaptive Cruise Control (ACC) is a driver assistance system – that detects vehicles driving in front – calculates their speed and – controls the brakes and engine to maintain the required distance. THE ACC SYSTEM IS A COMFORT SYSTEM AND NOT A SAFETY SYSTEM! The ACC system is an addition to the regular cruise control and the maximum speed control to be able to maintain a constant distance to the vehicle ahead. The ACC system can automatically decelerate and accelerate the vehicle. A distance sensor (radar sensor) integrated into the bumper provides information about what is happening at the front of the vehicle. The speed is then controlled to maintain a constant distance from the vehicle in front. If the vehicle approaches another vehicle in front of it in the same lane, the vehicle's own speed is reduced and a safe distance is maintained. The system automatically accelerates up to the set desired speed and brakes with a limited delay to correct the speed and distance to the vehicle ahead. Braking is performed using the engine drag torque, and if additional braking power is required, the engine brake, primary retarder, secondary retarder or service brake is also used. For safety reasons, braking is restricted to about 30% of the maximum possible deceleration value. The driver can override the function at any time by accelerating or braking. If no vehicle is detected in front, the ACC system functions like the regular cruise control or maximum speed control function. As soon as the driver starts to overtake or the vehicle in front changes out of the same lane, the vehicle under ACC control automatically accelerates to the previously set target speed. Limits of the ACC system At present, the ACC system is only designed for use when driving on the motorway or similar fast main roads, since bends in the road must not be tighter than a particular minimum radius in order for the system to function reliably. Tight bends can result in the target vehicle being lost. The ACC system should thus be switched off before you leave the motorway or main road otherwise there is a risk that the system may accelerate the vehicle inadvertently. The system does not detect stationary targets such as broken-down vehicles, vehicles at the tail end of a trafc jam, bridge pillars or road signs. As a result, the driver always has to keep an eye on trafc and respond accordingly. The system may intermittently stop working in bad weather such as heavy rain, driving snow or if the sensor cover is contaminated. The system is therefore only an aid to driving and does not negate the driver's responsibility to pay attention to the trafc. In those rare cases when the automatic delay by the limited braking is insufcient, the driver needs to override the system manually. Note: The driver displays, text messages on the driver display, critical driving situations, general accident risks and possible driver displays for ACC ON, ACC OFF and cruise control/road speed limiter functions are explained in the Operator's Manual. CAUTION: danger of accidents! – The driver is always responsible for keeping his distance from the vehicle in front and for his speed. – The driver must brake the vehicle himself in certain trafc conditions. – Switch off the ACC system before leaving the motorway or dual carriageway. – The ACC system only detects MOVING vehicles, NOT stationary vehicles. – Do not use the ACC system if there is black ice on the road or if visibility is poor (e.g. fog, snow, etc.). Interfaces to other systems The system communicates with the control unit using a data bus. See “CAN data bus system structure” for a control unit diagram. A fault in or a failure of a system (e.g. EBS, EDC, ECAS, etc.) is notied to the central on-board computer 2 via the driveline CAN data bus. If there is no anticipated and regular CAN message, the system detects a timeout fault and displays it. Example: in the event that a control unit malfunctions and no longer takes part in communication. The central on-board computer 2 sends the signal to the combined instrument via the combined instrument CAN data bus. The fault is displayed on the combined instrument using check lamps, symbols and texts. 26

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DEVICE DESCRIPTION CAN data bus system structure TGA/TGL/TGM

(A143) (A144) (A148) (A302)

(A312) (A330)

(A384) (A402a) (A402b) (A403)

(A407) (A408) (A435) (A479) (A574) (A577)

ECAS control unit Retarder/intarder control unit Radio/cassette player Central on-board computer 2 (ZBR2) with terminating resistor, combined instrument CAN Customer-specic control module with terminating resistor, body CAN Control unit, TipMatic (on gearbox) (TGA only) with terminating resistor, driveline CAN Rear-axle steering control unit (RAS-EC) EBS control unit, WABCO (TGL/TGM only) EBS control unit, KNORR (TGA only) Vehicle management computer with terminating resistors, engine control CAN and driveline CAN Combined instrument with terminating resistor, Highline CAN Tachograph with terminating resistor, combined instrument CAN EDC control unit with terminating resistor, engine control CAN Control unit, ACC (TGA) Control element, MMI On-board telematics module

T 39

(A590) Control unit, TipMatic lite (on gearbox) (TGL/TGM) (A609) Control unit, LGS (TGA) (A635) Truck Gate with terminating resistor, Highline CAN (A808) Denoxtronic supply module (A . . . ) Other systems can be networked (AB) Body manufacturer electronics at CAN connection, e.g. FMS systems (X200) Diagnostics plug (Body Body manufacturer CAN data bus CAN) (simultaneously connection for FMS interface) (Highline Highline CAN data bus CAN) (HDOBD)CAN data bus Heavy Duty On-Board Diagnosis (Combined CAN data bus for combined instrument instrument CAN) (Engine CAN data bus, engine control control CAN) (Driveline Driveline CAN data bus CAN)

2nd edition

27

DEVICE DESCRIPTION TGA (heavy-duty semitrailer tractor)

(A143) ECAS control unit (A266) Converter-clutch unit/retarder control unit (A302) Central on-board computer 2 (ZBR2) with terminating resistor, combined instrument CAN (A312) Customer-specic control module with terminating resistor, body CAN (A330) Control unit, TipMatic (A384) Rear-axle steering control unit (RAS-EC) (A402) EBS control unit, KNORR (A403) Vehicle management computer with terminating resistors, engine control CAN and driveline CAN (A407) Combined instrument with terminating resistor, Highline CAN (A408) Tachograph with terminating resistor, combined instrument CAN (A409) ECAM control unit with terminating resistor, driveline CAN (A435) EDC control unit with (Common Rail, master) (A479) ACC control unit (A570) EDC control unit (Common Rail, slave) with terminating resistor, engine control CAN

28

T 39

(A574) Control unit, MMI, with terminating resistor, Highline CAN (A577) On-board telematics module (A609) LGS control unit (A688) Auxiliary management computer (A808) Denoxtronic supply module (A . . . ) Other systems can be networked (AB) Body manufacturer electronics at CAN connection, e.g. FMS systems (X200) Diagnostics plug (Body Body manufacturer CAN data bus CAN) (simultaneously connection for FMS interface) (Highline Highline CAN data bus CAN) (HDOBD)CAN data bus Heavy Duty On-Board Diagnosis (Combined CAN data bus for combined instrument instrument CAN) (Engine CAN data bus, engine control control CAN) (Driveline Driveline CAN data bus CAN)

2nd edition

DEVICE DESCRIPTION TGS/TGX

(A143) ECAS control unit (A250) Control unit, air-conditioning system /auxiliary air conditioning system (A266) Converter-clutch unit/retarder control unit (A302) Central on-board computer 2 (ZBR2) with terminating resistor, combined instrument CAN (A312) Customer-specic control module with terminating resistor, body CAN (A330) TipMatic control unit (on gearbox) with terminating resistor, driveline CAN (A384) Rear-axle steering control unit (RAS-EC) (A402) EBS/ESP control unit (A403) Vehicle management computer with terminating resistors, engine control CAN and driveline CAN (A407) Combined instrument (A408) Tachograph with terminating resistor, combined instrument CAN (A435) EDC control unit with terminating resistor, engine control CAN (A479) ACC control unit (A564) Radio/CD player

(A577) (A609) (A626) (A808) (A . . . ) (AB) (Body CAN)

On-board telematics module LGS control unit Hydrostatic front-wheel drive control unit Denoxtronic supply module Other systems can be networked Body manufacturer electronics on CAN connection, e.g. FMS systems Body manufacturer CAN data bus (simultaneously connection for FMS interface) Diagnostics plug Highline CAN data bus

(X200) (Highline CAN) (HDOBD)CAN data bus Heavy Duty On-Board Diagnosis (Combined CAN data bus for combined instrument instrument CAN) (Engine CAN data bus, engine control control CAN) (Driveline Driveline CAN data bus CAN)

Bus/coach with TEPS (TEPS – Twin-Electronic-Platform-System, shared data exchange)

T 39

2nd edition

29

DEVICE DESCRIPTION

(A143) ECAS control unit (A144) Retarder control unit (A302) Central on-board computer 2 (ZBR2) with terminating resistor, combined instrument CAN (A330) TipMatic control unit (on gearbox) (A360) Multiplex central computer (ZBRO) (A402) EBS control unit, KNORR (A403) Vehicle management computer with terminating resistors, engine control CAN and driveline CAN (A407) Combined instrument with terminating resistors, combined instrument CAN and Highline CAN (A408) Tachograph with terminating resistor, combined instrument CAN (A409) ECAM control unit with terminating resistor, driveline CAN (A435) EDC control unit with terminating resistor, engine control CAN (A574) Control unit, MMI, with terminating resistor, Highline CAN 30

T 39

(A . . . ) Other systems can be networked (A411) Multiplex node, front, left 2-M 1.1 (A412) Multiplex node (customer special request) 2-M 1.2 (A413) Multiplex node, control units 2-M 1.3 (A414) Multiplex node (customer special request) 2-M 1.4 (A415) Multiplex node, roof 2-M 1.5 (A416) Multiplex node (customer special request) 2-M 1.6 (A417) Multiplex node (customer special request) 2-M 1.7 (A418) Multiplex node, rear, right 2-M 1.8 (A421) Multiplex node, front, right 2-M 2.1 (A422) Multiplex node (customer special request) 2-M 2.2 (A423) Multiplex node, middle of vehicle 2-M 2.3 (A424) Multiplex node, integrated on-board information system 2-M 2.4 (A425) Multiplex node, rear 3 2-M 2.5 (A426) Multiplex node (customer special request) 2-M 2.6 2nd edition

DEVICE DESCRIPTION (A427) Multiplex node, trailer 2-M 2.7 (A428) Multiplex node, rear, left 2-M 2.8 (R195) Terminating resistor, front, basis CAN 1 (R196) Terminating resistor, rear, basis CAN 1 (R197) Terminating resistor, front, basis CAN 2 (R198) Terminating resistor, rear, basis CAN 2 (Combined CAN data bus for combined instrument instrument CAN) (Highline Highline CAN data bus CAN) (Engine CAN data bus, engine control control CAN) (Driveline Driveline CAN data bus CAN)

T 39

2nd edition

31

DEVICE DESCRIPTION FUNCTIONAL DESCRIPTION ACC system structure without ESP – old version (TGA)

(A302) Central on-board computer 2 (A402) EBS control unit (A403) Vehicle management computer (A407) Highline combined instrument (A408) Tachograph (A429) Stalk switch for cruise control/gearbox (A435) EDC control unit (A479) ACC control unit (B476) ESP/ACC yaw rate sensor (B574) ACC distance sensor (S284) Cruise control/road speed limiter switch (S479) Continuous brake switch (S550) Button, ACC, distance (T119) Modular voltage converter (Combined CAN data bus for combined instrument instrument CAN) (Engine Engine CAN data bus control CAN) (S-CAN) Sensor CAN data bus (Driveline Driveline CAN data bus CAN)

32

T 39

2nd edition

DEVICE DESCRIPTION ACC system structure without ESP – old version (TGS/TGX)

(A302) Central on-board computer 2 (A402) EBS control unit (A403) Vehicle management computer (A407) Highline combined instrument (A408) Tachograph (A435) EDC control unit (A479) ACC control unit (A943) Multi-function steering wheel (B476) ESP/ACC yaw rate sensor (B574) ACC distance sensor (S550) Button, ACC, distance (T119) Modular voltage converter (Combined CAN data bus for combined instrument instrument CAN) (Engine Engine CAN data bus control CAN) (S-CAN) Sensor CAN data bus (Driveline Driveline CAN data bus CAN) (LIN) LIN data bus

T 39

2nd edition

33

DEVICE DESCRIPTION ACC system structure with ESP – old version (TGA)

(A302) Central on-board computer 2 (A402) EBS control unit (A403) Vehicle management computer (A407) Highline combined instrument (A408) Tachograph (A429) Stalk switch for cruise control/gearbox (A435) EDC control unit (A479) ACC control unit (B476) ESP/ACC yaw rate sensor (B574) ACC distance sensor (S284) Cruise control/road speed limiter switch (S479) Continuous brake switch (S550) Button, ACC, distance (T119) Modular voltage converter (Combined CAN data bus for combined instrument instrument CAN) (Engine Engine CAN data bus control CAN) (S-CAN) Sensor CAN data bus (Driveline Driveline CAN data bus CAN)

34

T 39

2nd edition

DEVICE DESCRIPTION ACC system structure with ESP – old version (TGS/TGX)

(A302) Central on-board computer 2 (A402) EBS control unit (A403) Vehicle management computer (A407) Highline combined instrument (A408) Tachograph (A435) EDC control unit (A479) ACC control unit (A943) Multi-function steering wheel (B476) ESP/ACC yaw rate sensor (B574) ACC distance sensor (S550) Button, ACC, distance (T119) Modular voltage converter (Combined CAN data bus for combined instrument instrument CAN) (Engine Engine CAN data bus control CAN) (S-CAN) Sensor CAN data bus (Driveline Driveline CAN data bus CAN) (LIN) LIN data bus

T 39

2nd edition

35

DEVICE DESCRIPTION ACC system structure with ESP – old version (P11/P12/P14/P15/P16)

(A302) Central on-board computer 2 (A402) EBS control unit (A403) Vehicle management computer (A407) Combined instrument (A408) Tachograph (A429) Stalk switch for cruise control/gearbox (A435) EDC control unit (A479) ACC control unit (B476) ESP/ACC yaw rate sensor (B574) ACC distance sensor (S550) Button, ACC, distance (T119) Modular voltage converter (Combined CAN data bus for combined instrument instrument CAN) (Engine Engine CAN data bus control CAN) (S-CAN) Sensor CAN data bus (Driveline Driveline CAN data bus CAN)

36

T 39

2nd edition

DEVICE DESCRIPTION ACC system structure with/without ESP – new version (TGS/TGX)

(A302) Central on-board computer 2 (A402) EBS control unit (A403) Vehicle management computer (A407) Highline combined instrument (A408) Tachograph (A435) EDC control unit (A479) ACC control unit (A943) Multi-function steering wheel (B476) ESP/ACC yaw rate sensor (B574) ACC distance sensor (S550) Button, ACC, distance (Combined CAN data bus for combined instrument instrument CAN) (Engine Engine CAN data bus control CAN) (S-CAN) Sensor CAN data bus (Driveline Driveline CAN data bus CAN) (LIN) LIN data bus

T 39

2nd edition

37

DEVICE DESCRIPTION ACC system structure with ESP – new version (P11/P12/P14/P15/P16)

(A302) Central on-board computer 2 (A402) EBS control unit (A403) Vehicle management computer (A407) Combined instrument (A408) Tachograph (A435) EDC control unit (A479) ACC control unit (A943) Multi-function steering wheel (B476) ESP/ACC yaw rate sensor (B574) ACC distance sensor (S550) Button, ACC, distance (Combined CAN data bus for combined instrument instrument CAN) (Engine Engine CAN data bus control CAN) (S-CAN) Sensor CAN data bus (Driveline Driveline CAN data bus CAN) (LIN) LIN data bus

38

T 39

2nd edition

DEVICE DESCRIPTION ACC control unit (A479) The operating voltage of the ACC control unit is 24 V. The power supply comes from the central electrical system (A100). The ACC control unit is protected by the following fuses: F414, fuse ACC terminal 30 (battery), F413, fuse ACC terminal 15 (ignition) and F628, fuse terminal 15 (in P11/P12/P14/P15/P16 only).

In vehicles without ESP, the ACC control unit communicates with the ACC distance sensor (B574) and the yaw rate sensor (B476) via the sensor CAN data bus. In vehicles with ESP, the ACC control unit only communicates with the ACC distance sensor via the sensor CAN data bus. To receive the signals from the yaw rate sensor, the ACC control unit communicates with the EBS control unit (A402) via the driveline CAN data bus. As from July 2010 the yaw rate sensor (B476) is no longer directly connected to the ACC control unit (A479). It is supplied with the required data from the EBS control unit (A402). Pressing the ACC distance button (S550) sends the signals directly to the central on-board computer 2 (A302). From there, the signals are sent to the ACC control unit via the driveline CAN data bus. If, in vehicles without multi-function steering wheel (A943), the cruise control/gearbox stalk switch (A429), cruise control/road speed limiter switch (S284) and the continuous brake switch (S479) are actuated, the signals are sent directly to the vehicle management computer (A403). From there, the signals are sent to the ACC control unit via the driveline CAN data bus. In vehicles with multi-function steering wheel (A943), ACC is switched on if the ignition is “ON” and the continuous brake is activated. When the ignition is switched “ON”, the continuous brake is switched on automatically. The check lamp in the continuous brake button (S1133) will remain off. The cruise control/road speed limiter switch (S284) is not required because the cruise control/road speed limiter function is provided by a switch integrated in the multi-function steering wheel. This switch is also used to switch ACC on and off. The signals are sent directly to the vehicle management computer. From there, the signals are sent to the ACC control unit via the driveline CAN data bus. The ACC control unit uses this data to calculate the best possible approach strategy and uses the CAN data bus and the vehicle management computer to control the EDC control unit, engine brake, retarder/intarder control unit and the EBS control unit. This way deceleration or acceleration is actively controlled along with the vehicle speed. The ACC control unit also allows the driver to override ACC settings. The ACC can only be used to control the vehicle if all of the required messages and switch positions are satised and the driver does not override the system. Sensor parameters required for ACC are stored in the ACC control unit. For this reason, it is necessary to pair-up the distance sensor and the ACC control unit. When comparing versions of ACC control units and vehicle management computers and during the pairing of distance sensor and ACC control unit, the vehicle identier is recorded. This is performed by calibrating the distance sensor and parameterising the control unit.

T 39

2nd edition

39

DEVICE DESCRIPTION Plug assignment

Plug connector X1: TGA Pin

Line no.

Designation

1

60030

Power supply, terminal 30 ACC fuse (terminal 30) (F414)

2

60029

Power supply, terminal 15 ACC fuse terminal 15 (F413)

3

31000

Ground point, cab, next to central electrical system (X1644)

4-9

—–

10

red/yellow

11

—–

12

yellow/red

13

—–

14

blue/red

Driveline CAN data bus, High signal Central on-board computer 2 (A302 pin M/1)

15

blue/white

Driveline CAN data bus, Low signal Central on-board computer 2 (A302 pin M/7)

16 - 17

—–

18

64205

not used Sensor CAN data bus, High signal ACC distance sensor (B574 pin 11) not used Sensor CAN data bus, Low signal ACC distance sensor (B574 pin 10) not used

not used Diagnostic communication line using 21-pin potential distributor of the communication line (X2544), connected to plug conn. for diagnosis (MAN-cats; X200, pin 3)

The plug connectors X2, X3 and X4 are not used. Plug connector X1: TGS/TGX

40

Pin

Line no.

Designation

1

60030

Power supply, terminal 30 ACC fuse (terminal 30) (F414)

2

16000

Power supply, terminal 15 Potential distributor, line 16000 (X4645)

3

31000

Ground point, cab, next to central electrical system (X1644)

4-9

—–

10

red/yellow

11

—–

12

yellow/red

13

—–

not used Sensor CAN data bus, High signal Old version: ACC distance sensor (B574 pin 11) New version: ACC distance sensor (B574 pin 4) not used Sensor CAN data bus, Low signal Old version: ACC distance sensor (B574 pin 10) New version: ACC distance sensor (B574 pin 5) not used

T 39

2nd edition

DEVICE DESCRIPTION Pin

Line no.

Designation

14

blue/red

Driveline CAN data bus, High signal Central on-board computer 2 (A302 pin M/1)

15

blue/white

Driveline CAN data bus, Low signal Central on-board computer 2 (A302 pin M/7)

16 - 17

—–

18

64205

not used Diagnostic communication line 21-pin potential distributor, communication line (X2544)

The plug connectors X2, X3 and X4 are not used. Plug connector X1: P11/P12/P14/P15/P16 Pin

Line no.

Designation

1

60030

Power supply, terminal 30 ACC fuse (terminal 30) (F414)

2

16000

Power supply, terminal 15 Old version: ACC fuse terminal 15 (F413) New version: Fuse for terminal 15 (F628)

3

31000

Ground Central electrical system (A100 connection 92)

4-9

—–

10

yellow/red

11

—–

12

red/yellow

13

—–

14

blue/red

Driveline CAN data bus, High signal Central on-board computer 2 (A302 pin M/1)

15

blue/white

Driveline CAN data bus, Low signal Central on-board computer 2 (A302 pin M/7)

16 - 17

—–

18

64205

not used Sensor CAN data bus, High signal Old version: ACC distance sensor (B574 pin 11) New version: ACC distance sensor (B574 pin 4) not used Sensor CAN data bus, Low signal Old version: ACC distance sensor (B574 pin 10) New version: ACC distance sensor (B574 pin 5) not used

not used Diagnostic communication line 21-pin potential distributor, communication line (X2544)

The plug connectors X2, X3 and X4 are not used. Repair instructions – Removing and tting the control unit Parameterisation is not required for removing or tting a present ACC control unit. – Replacing a control unit If the ACC control unit is replaced, the ACC control unit must be parameterised (pairing). – Parameterising the control unit Parameterisation is also required if the ACC control unit was not parameterised correctly.

T 39

2nd edition

41

DEVICE DESCRIPTION Yaw rate sensor (B476) Please observe that there are three versions of the yaw rate sensor (B476): – Yaw rate sensor 81.25937-0050 (TGA/TGS/TGX); Knorr brake – Yaw rate sensor 81.25937-0051 (TGA/TGS/TGX); Knorr brake – Yaw rate sensor 85.25808-6001 (P11/P12/P14/P15/P16); Wabco Yaw rate sensor 81.25937-0050; Knorr-Bremse The operating voltage of the yaw rate sensor is 12 V. The power supply comes from the central electrical system (A100). A voltage converter (T119) ensures that the yaw rate sensor is not supplied with 24 V but with the required 12 V. In vehicles without ESP, the yaw rate sensor (B476) communicates with the ACC distance sensor (B574) and the ACC control unit (A479) via the sensor CAN data bus. In vehicles with ESP, the yaw rate sensor (B476) communicates with the EBS control unit (A402) via the sensor CAN data bus. The signals are sent from the EBS control unit to the ACC control unit (A479) via the driveline CAN data bus. The sensor CAN data bus is equipped with two terminating resistors with 120 Ω each. In vehicles without ESP, one terminating resistor is tted in the ACC control unit and one in the yaw rate sensor. In vehicles with ESP, one terminating resistor is tted in the ACC control unit and one ACC sensor CAN terminating resistor (R258) is separately tted on the plug connector “Cab member, left ACC (X3287)”. Measuring principle of the yaw rate sensor

The yaw rate sensor detects your vehicle's direction of travel. This is a micromechanical, combined yaw rate and lateral acceleration sensor. If the vehicle is equipped with an electronic stability program (ESP), this yaw rate sensor signal, which is accessed via the driveline CAN data bus, is used. The mass mounted in the yaw rate sensor moves in the direction of rotation = yaw rate (1), transverse direction = lateral acceleration (2) and longitudinal direction = longitudinal acceleration (3). Electrical signals are generated from the movements and accelerations in these directions and the ACC control unit (A479) calculates the impact and direction of the change to the vehicle's direction. The ACC control unit must know the vehicle's change of direction to be able to allocate vehicles in the own lane (when driving through corners or going straight ahead) that are detected by the ACC distance sensor (B574).

42

T 39

2nd edition

DEVICE DESCRIPTION Plug assignment

Pin

Line no.

Designation

1

165

12 V power supply

2

166

Ground

3

167

Sensor CAN data bus, High signal

4

168

Sensor CAN data bus, Low signal

Technical data: Operating voltage:

8.2 - 16 V

Nominal voltage:

12 V

Test voltage:

14 V

Operating temperature:

-40°C to +85°C

Repair instructions – Installation position

It is essential to observe the correct installation position of the yaw rate sensor to avoid the occurrence of SPN diagnostic codes 04482, 04483, 04581 and 04582. The direction indicated on the adhesive label (1) must always point along the vehicle, not across the vehicle. The plug connector (2) points in or against the direction of travel, depending on the vehicle version (see “Yaw rate sensor installation location”). In the case of repair work/conversions on the vehicle, you must not change the installation location and the installation position of the yaw rate sensor otherwise the function of the yaw rate sensor cannot be ensured. Please only perform modications after coordinating them with MAN.

T 39

2nd edition

43

DEVICE DESCRIPTION – Opening for pressure compensation

There is a bore (1) for pressure compensation on the bottom side of the housing. If you are required to paint the chassis after repair work/conversions, please ensure not to cover the bore (1) with paint. Please do not block or cover the bore in any other way. – Adhesive label "Keep Clear"

The installation location/installation position of the yaw rate sensor differs depending on the vehicle version. For this reason, the “Keep Clear” label is applied in some cases. In case of repair work/conversions on the vehicle, the yaw rate sensor must not be subject to loads of any kind (stepping on it, pressure, impact). If the chassis is painted, the adhesive label must be covered beforehand. Please remove the cover after painting. The adhesive label must be visible at all times. – Removing/replacing the yaw rate sensor The yaw rate sensor must not be dropped (impact), to avoid malfunctions in the respective system (ESP, ACC, etc.). Yaw rate sensor 81.25937-0051; Knorr-Bremse The operating voltage of the yaw rate sensor is 12 V. The power supply comes from the central electrical system (A100). A voltage converter (T119) ensures that the yaw rate sensor is not supplied with 24 V but with the required 12 V. In vehicles without ESP, the yaw rate sensor (B476) communicates with the ACC distance sensor (B574) and the ACC control unit (A479) via the sensor CAN data bus. In vehicles with ESP, the yaw rate sensor (B476) communicates with the EBS control unit (A402) via the sensor CAN data bus. The signals are sent from the EBS control unit to the ACC control unit (A479) via the driveline CAN data bus. As from July 2010 the yaw rate sensor (B476) is no longer directly connected to the ACC control unit (A479). It is supplied with the required data from the EBS control unit (A402). The sensor CAN data bus is equipped with two terminating resistors with 120 Ω each. In vehicles without ESP, one terminating resistor is tted in the ACC control unit and one in the yaw rate sensor. In vehicles with ESP, one terminating resistor is tted in the ACC control unit and one ACC sensor CAN terminating resistor 44

T 39

2nd edition

DEVICE DESCRIPTION (R258) is separately tted on the plug connector “Cab member, left ACC (X3287)”. As from the beginning of July 2010, one terminating resistor is tted in the ACC control unit and one ACC sensor CAN terminating resistor (R258) is separately tted on the plug connector “Cab member, left ACC (X3287)”, even in vehicles without ESP. The yaw rate sensor is no longer connected to the ACC control unit (A479) but to the EBS control unit (A402). Measuring principle of the yaw rate sensor

The yaw rate sensor detects your vehicle's direction of travel. This is a micromechanical, combined yaw rate and lateral acceleration sensor. If the vehicle is equipped with an electronic stability program (ESP), this yaw rate sensor signal, which is accessed via the driveline CAN data bus, is used. The mass mounted in the yaw rate sensor moves in the direction of rotation = yaw rate (1), transverse direction = lateral acceleration (2) and longitudinal direction = longitudinal acceleration (3). Electrical signals are generated from the movements and accelerations in these directions and the ACC control unit (A479) calculates the impact and direction of the change to the vehicle's direction. The ACC control unit must know the vehicle's change of direction to be able to allocate vehicles in the own lane (when driving through corners or going straight ahead) that are detected by the ACC distance sensor (B574).

T 39

2nd edition

45

DEVICE DESCRIPTION Plug assignment

Pin

Line no.

Designation

1

165

12 V power supply

2

166

Ground

3

167

Sensor CAN data bus, High signal

4

168

Sensor CAN data bus, Low signal

Technical data: Operating voltage:

7 - 18 V

Nominal voltage:

12 V

Test voltage:

14 V

Operating temperature:

-40°C to +80°C

Repair instructions – Installation position

It is essential to observe the correct installation position of the yaw rate sensor to avoid the occurrence of SPN diagnostic codes 04482, 04483, 04581 and 04582. The arrows (1) attached to the adhesive label mark the direction of travel in the respective installation position. In the case of repair work/conversions on the vehicle, you must not change the installation location and the installation position of the yaw rate sensor otherwise the function of the yaw rate sensor cannot be ensured. Please only perform modications after coordinating them with MAN. The yaw rate sensor must not be subject to loads of any kind (stepping on it, pressure, impact, etc.).

46

T 39

2nd edition

DEVICE DESCRIPTION – Opening for pressure compensation

There is an opening (1) for pressure compensation on the bottom side of the housing. If you are required to paint the chassis after repair work/conversions, please ensure not to cover the opening (1) with paint. Please do not block or cover the opening in any other way. – Removing/replacing the yaw rate sensor The yaw rate sensor must not be dropped (impact), to avoid malfunctions in the respective system (ESP, ACC, etc.). This yaw rate sensor may be tted offset in all four directions. The installation position of the yaw rate sensor must be parameterised in the EBS control unit and must not be changed. Yaw rate sensor 85.25808-6001; Wabco It is a micromechanical, combined yaw rate and lateral acceleration sensor. The operating voltage of the yaw rate sensor is 24 V. The power supply comes from the central electrical system (A100). The output signals (yaw rate and lateral acceleration) are transferred to the central brake unit via a CAN sensor. In vehicles with ESP, the yaw rate sensor (B476) communicates with the EBS control unit (A402) via the sensor CAN data bus. The signals are sent from the EBS control unit to the ACC control unit via the driveline CAN data bus.

Measuring principle of the yaw rate sensor The yaw rate sensor contains two micromechanical oscillating masses. Each of the masses has two micromechanical acceleration sensors integrated into their surface. These register the Coriolis acceleration. The measuring principle is based on the Coriolis force that is caused by a rotational movement (yaw rate) at right angles to the given oscillation direction of the seismic masses. The lateral acceleration is measured by an additional micromechanical acceleration sensor. The yaw rate sensor signal is calibrated when the switch is turned on. Standstill calibration (normal case) is performed if the vehicle is at a standstill; rapid calibration is performed if the vehicle is already driving. The calculated offset value is continuously compared with the permitted limit value. The standstill calibration is performed when the wheel speed, the steering angle and the yaw rate indicate that the vehicle is at a standstill. The procedure is cancelled if “Driving” is detected before the end of calibration. T 39

2nd edition

47

DEVICE DESCRIPTION Rapid calibration only takes place once per switch-on cycle (switch on) if it was not possible to perform a standstill calibration previously. The offset is calculated as the difference between the measured and calculated yaw rate. The normal calibration is performed during operation after the standstill or rapid calibration has been performed. The principle of the normal calibration is the same as for rapid calibration. The sensitivity of the yaw rate sensor is measured during cornering with the help of a calculated reference yaw rate and the measured yaw rate. Plug assignment

Pin

Line no.

Designation

1

165

24 V power supply

2

166

Ground

3

167

Sensor CAN data bus, High signal

4

168

Sensor CAN data bus, Low signal

Technical data: Operating voltage:

8 - 32 V

Nominal voltage:

24 V

Test voltage:

27 V

Operating temperature:

-40°C to +80°C

Repair instructions – Installation position It is essential to observe the correct installation position of the yaw rate sensor to avoid the occurrence of SPN diagnostic codes 04482, 04483, 04581 and 04582. In the case of repair work/conversions on the vehicle, you must not change the installation location and the installation position of the yaw rate sensor otherwise the function of the yaw rate sensor cannot be ensured. Please only perform modications after coordinating them with MAN. The yaw rate sensor must not be subject to loads of any kind (stepping on it, pressure, impact, etc.). Following service work (removing, tting, replacing), the yaw rate sensor must be calibrated with the diagnostics function of the MAN-cats® II test system. This is done by sending a calibration request to the sensors via the EBS control unit. – Removing/replacing the yaw rate sensor The yaw rate sensor must not be dropped (impact), to avoid malfunctions in the respective system (ESP, ACC, etc.). The installation position of the yaw rate sensor must be parameterised in the EBS control unit and must not be changed.

48

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DEVICE DESCRIPTION ACC distance sensor (B574) Please observe that there are two different versions of the ACC distance sensor (B574): – ACC distance sensor 81.27610-0024 (TGA/TGS/TGX) and 81.27610-0013 (P11, P12, P14, P15, P16) – old version; TRW Automotive Electronics – ACC distance sensor 81.27610-0023 – new version; TRW Automotive Electronics ACC distance sensor 81.27610-0013 and 81.27610-0024 – old version; TRW Automotive Electronics The operating voltage of the ACC distance sensor is 12 V. The power supply comes from the central electrical system (A100). A voltage converter (T119) ensures that the ACC distance sensor is not supplied with 24 V but with the required 12 V.

A radar sensor (also called an antenna) works as the distance sensor in high-frequency operation and a transmission frequency of 76 - 77 GHz. The distance sensor is tted in the vehicle's bumper. Its detection range is 150 metres and the beam angle is approx. ±5.5°. The yaw rate sensor signal detects the current direction of the road and allocates vehicles to the lanes. Radar beams are reected by vehicles in front and subsequently evaluated. This means the system detects the distance and relative speed of vehicles in front of it in the same lane. This information is sent to the ACC control unit via the sensor CAN data bus. Sensor parameters required for ACC are stored in the ACC control unit. For this reason, it is necessary to pair-up the distance sensor and the ACC control unit. When comparing versions of ACC control units and vehicle management computers and during the pairing of distance sensor and ACC control unit, the vehicle identier is recorded. This is performed by calibrating the distance sensor and parameterising the control unit. Plug assignment

Pin

Line no.

Designation

1

165

12 V power supply

2

166

Ground

10

168

Sensor CAN data bus, Low signal

11

167

Sensor CAN data bus, High signal

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DEVICE DESCRIPTION Panel TGA:

TGS/TGX:

A panel (1) is tted in front of the distance sensor to act as mechanical protection. Note: In order to allow radar beams to pass through the panel, the panel must not be painted. Calibration The ACC distance sensor must be calibrated – After modications to the running gear (springs, tyres, wheels, etc.) – After every accident – After replacing the ACC distance sensor – After replacing the bumper – Whenever you detect displacement on the bolt securing lacquer – Whenever there is no bolt securing lacquer High-frequency operation is deactivated before calibration, i.e. ACC is without function. High-frequency mode is not re-established until completing correct calibration. This means that ACC is ready for operation again. TGA:

TGS/TGX:

The distance sensor is aligned in parallel to the driven rear axle. The distance sensor is equipped with a mirror (1) (optical axis). This involves aligning the distance sensor correctly according to the specied values for AZOF mirror offset (horizontal position of the distance sensor) and ELOF mirror offset (vertical position of the distance sensor). This is performed using MAN-cats® II. Its variance from the radar axis (2) is indicated on the adhesive label on the bottom side of the housing and also saved in the EEPROM of the distance sensor. Radar axis refers to the central axis of the distance sensor's radar eld of view. The optical axis is perpendicular to the small square mirror of the distance sensor. 50

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DEVICE DESCRIPTION

AZOF = horizontal position of the distance sensor signal ELOF = vertical position of the distance sensor signal There is an adhesive label on the rear side of the distance sensor. Values for AZOF mirror offset and ELOF mirror offset (1) are indicated here. This basic setting was carried out by the supplier. MAN-cats® II reads out the values indicated on the distance sensor. During calibration, these values are set as variance from the centre of the scale above the two adjusting screws on the distance sensor (see Chapter “Calibrating the ACC distance sensor (B574)”). Technical data: Operating voltage:

8.2 - 16 V

Nominal voltage:

12 V

Test voltage:

14 V

ACC distance sensor 81.27610-0023 – new version; TRW Automotive Electronics The operating voltage of the ACC distance sensor is 24 V. The power supply comes from the central electrical system (A100).

A radar sensor (also called an antenna) works as the distance sensor in high-frequency operation and a transmission frequency of 76 - 77 GHz. The distance sensor is tted in the vehicle's bumper. Its detection range is 200 metres and the beam angle is approx. ±5.5°. The yaw rate sensor signal detects the current direction of the road and allocates vehicles to the lanes. Radar beams are reected by vehicles in front and subsequently evaluated. This means the system detects the distance and relative speed of vehicles in front of it in the same lane. This information is sent to the ACC control unit via the sensor CAN data bus. Sensor parameters required for ACC are stored in the ACC control unit. For this reason, it is necessary to pair-up the distance sensor and the ACC control unit. When comparing versions of ACC control units and vehicle management computers and during the pairing of distance sensor and ACC control unit, the vehicle identier is recorded. This is performed by calibrating the distance sensor and parameterising the control unit. T 39

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DEVICE DESCRIPTION Plug assignment TGS, TGX, P11, P12, P14, P15, P16

Pin

Line no.

Designation

4

167

Sensor CAN data bus, High signal

5

168

Sensor CAN data bus, Low signal

9

166

Ground

10

165

24 V power supply

Panel TGS/TGX:

A panel (1) is tted in front of the distance sensor to act as mechanical protection.

Panel (1) on vehicles without light array Panel (2) on vehicles with light array

Note: In order to allow radar beams to pass through the panel, the panel must not be painted. Calibration The ACC distance sensor must be calibrated – After modications to the running gear (springs, tyres, wheels, etc.) – After every accident – After replacing the ACC distance sensor – Whenever you detect displacement on the bolt securing lacquer – Whenever there is no bolt securing lacquer This ACC distance sensor is frame-mounted and does not need to be recalibrated after the bumper is replaced. High-frequency operation is deactivated before calibration, i.e. ACC is without function. High-frequency mode is not re-established until completing correct calibration. This means that ACC is ready for operation again. TGS/TGX:

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The distance sensor is aligned in parallel to the driven rear axle. The distance sensor is equipped with a mirror (1) (optical axis). This involves aligning the distance sensor correctly according to the specied values for AZOF mirror offset (horizontal position of the distance sensor) and ELOF mirror offset (vertical position of the distance sensor). This is performed using MAN-cats® II. Its variance from the radar axis (2) is indicated on the adhesive label on the bottom side of the housing and also saved in the EEPROM of the distance sensor. Radar axis refers to the central axis of the distance sensor's radar eld of view. The optical axis is perpendicular to the small square mirror of the distance sensor.

AZOF = horizontal position of the distance sensor signal ELOF = vertical position of the distance sensor signal There is an adhesive label on the rear side of the distance sensor. Values for AZOF mirror offset and ELOF mirror offset (1) are indicated here. This basic setting was carried out by the supplier. MAN-cats® II reads out the values indicated on the distance sensor. During calibration, these values are set as variance from the centre of the scale above the two adjusting screws on the distance sensor (see Chapter “Calibrating the ACC distance sensor (B574) (TGA/TGS/TGX)”). The designation AC20 (2) for the new version of the distance sensor can be found on the top right of the adhesive label. Technical data: Operating voltage:

9 - 32 V

Nominal voltage:

24 V

Repair instructions – Removing and tting the distance sensor Calibration is required subsequent to replacing/tting a present distance sensor. – Replacing the distance sensor If the distance sensor is replaced and the ACC control unit remains tted, you must subsequently calibrate the distance sensor and parameterise the ACC control unit. – Calibrating the distance sensor See Chapter “Calibrating the ACC distance sensor (B574)” T 39

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DEVICE DESCRIPTION Modular voltage converter (T119) The ACC distance sensor (B574) and the yaw rate sensor (B476) require a 12 V power supply. The task of the voltage converter is to convert the 24 V power supply into a 12 V power supply for the aforementioned sensors. The operating voltage of the voltage converter is 24 V. The power supply comes from the central electrical system (A100). The voltage converter is protected by the 12 V voltage converter fuse (F216) – terminal 30 (battery).

The voltage converter is equipped with a cooling element. The cooling element ensures that the voltage converter does not exceed the permitted operating temperature of between +85°C and approx. +95°C. Do not cover ventilating slits on the side of the voltage converter. The output voltage is reduced in case of an overload and short-circuit on the output of the voltage converter. The voltage converter deactivates itself in the following operating conditions until normal operating conditions are restored. See also SI 191302a. – Input voltage too low If the input voltage is below 18 V, the voltage converter deactivates all outputs after waiting for 30 sec. If the input voltage is between 18 V and 23 V, the voltage converter deactivates all outputs after waiting for 200 sec. As soon as the power supply exceeds 23.5 V, outputs required for ACC are reactivated. Note: The voltage converter starts up only at an input voltage of 16 V. – Permitted operating temperature exceeded If the cooling element temperature exceeds +100°C, the voltage converter deactivates the ACC outputs. Subsequently allow the cooling element of the voltage converter to cool down to below +85°C. After the temperature has fallen to below +85°C for more than 5 minutes, the voltage converter reactivates the outputs. – In the event of excess currents and voltages at the outputs In the event of overcurrent, please perform an overcurrent reset. You disconnect the ACC distance sensor (B574) and in vehicles without ESP you additionally disconnect the yaw rate sensor (B476) from the deactivated output of the voltage converter. Subsequently wait approx. one second. Then the ACC outputs are automatically reactivated. If the voltage converter does not switch itself back on, switch the ignition off and on. The ACC distance sensor and in vehicles without ESP additionally the yaw rate sensor is reconnected to the activated output of the voltage converter. The voltage converter switches off in the event of an overvoltage at the output > 19 V, and an overvoltage reset must be carried out. For this purpose, remove the 12 V voltage converter fuse (F216 – power supply of the voltage converter). Subsequently wait 60 seconds before reinserting the fuse. Important! It is possible that the voltage in the vehicle electrical system is too low in low temperatures. In this case, the voltage converter switches off the outputs to the ACC after the ignition has been “ON” for 3 minutes.

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DEVICE DESCRIPTION Technical data: Input: Operating temperature:

-40°C to +80°C

Operating voltage:

16 - 32V

Overvoltage:

36 V/1 hour at 40°C ambient temperature

Test voltage:

27.6V

Nominal voltage:

24 V

min. current at U = 16 V:

12 mA

max. current at U = 32 V:

17 A

Output: Nominal voltage:

13.5 - 14.2 V

Plug assignment

(1) Plug connector X1 code 1 – 24 V input voltage (2) Plug connector X2 – plug connector for ACC power supply, radio phone, radio, navigation

(3) Plug connector X3 code 2 – 12 V output voltage

Plug connector X1 code 1 – 24 V input voltage Pin

Line no.

Assignment

1

30012

24 V power supply, terminal 30 – Input voltage 12 V voltage converter fuse (F216)

2

31000

Ground TGA: Ground point, cab, behind instrument panel (X1642) TGS/TGX: Ground point, cab, next to central electrical system (X1644)

Plug connector X2 Pin

Line no.

3

75301

Output voltage (terminal 15) TGA: Terminal 15 adapter, 12 V modular voltage converter

60050

12 V power supply, ACC distance sensor (terminal 15) ACC without ESP: ESP/ACC yaw rate sensor (B476 pin 1) and ACC distance sensor (B574 pin 1) ACC with ESP: ACC distance sensor (B574 pin 1)

7

Assignment

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DEVICE DESCRIPTION Pin

Line no.

12

15002 16000

24 V power supply, terminal 15 – Input voltage TGA: Ignition lock plug connector (X1966) TGS/TGX: Potential distributor, line 16000 (X4645)

17

31030

Ground 12 V ACC distance sensor from voltage converter – ACC with ESP ACC distance sensor (B574 pin 2)

31030

Ground ACC distance sensor 12 V from voltage converter – ACC without ESP ESP/ACC yaw rate sensor (B476 pin 2) and ACC distance sensor (B574 pin 2)

18

Assignment

Plug connector X3 code 2 – 12 V output voltage

56

Pin

Line no.

Assignment

1

30325

12 V power supply socket 12 V socket (X723 pin +)

2

31034

12 V ground socket 12 V socket (X723 pin -)

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DEVICE DESCRIPTION ACC distance button (S550) – TGA

– TGS/TGX/P11/P12/P14/P15/P16

The ACC distance button enables the driver to reduce or increase the distance from the vehicle driving in front. The distance from the vehicle driving in front is reduced by pressing the button down. This is displayed at the top right of the display in the combined instrument. The number of arrows decreases. Pressing the button down establishes a connection to terminal 15 which means that the power supply is 24 V. This is communicated to the central on-board computer (A302). The distance from the vehicle driving in front is increased by pressing the button up. This is displayed at the top right of the display in the combined instrument. The number of arrows increases. Pressing the button up establishes a connection to ground which means that the power supply is 0 V. This is communicated to the central on-board computer (A302).

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DEVICE DESCRIPTION Internal circuit

Technical data: Operating voltage:

16 - 32V

Nominal voltage:

24 V

Test voltage:

27.6 V

Resistor R4:

47 kΩ (location lighting)

Plug assignment

TGA/P11/P12/P14/P15/P16

58

Pin

Line no.

Assignment

1

—–

2

60029

Power supply, terminal 15

3

60630

Request ACC nominal distance – Reduce distance Connected to ACC distance button (S550 pin 4)

4

60630

Request ACC nominal distance – Increase distance Connected to ACC distance button (S550 pin 3); central on-board computer 2 (A302 pin F2/2)

5

31000

Ground terminal 31 Connected to ACC distance button (S550 pin 7)

6

—–

not used

not used

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DEVICE DESCRIPTION Pin

Line no.

Assignment

7

31000

Ground terminal 31 Connected to ACC distance button (S550 pin 5)

8

58000

Power supply, terminal 58

TGS/TGX Pin

Line no.

Assignment

1

—–

2

31000

Ground terminal 31 Connected to ACC distance button (S550 pin 7); potential distributor, 21-pin, line 31000 (X2541)

3

60630

Request ACC nominal distance – Reduce distance Connected to ACC distance button (S550 pin 4)

4

60630

Request ACC nominal distance – Increase distance Central on-board computer 2 (A302 pin F2/2); connected to ACC range button (S550 pin 3)

5

16000

Power supply, terminal 15 Connected to ACC distance button (S550 pin 8); potential distributor, line 16000 (X4645)

6

—–

7

31000

Ground terminal 31 Connected to ACC distance button (S550 pin 2)

8

16000

Power supply, terminal 15 Connected to ACC distance button (S550 pin 5)

not used

not used

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DEVICE DESCRIPTION Cruise control/road speed limiter switch (S284)

Use: Vehicles without multi-function steering wheel Functions – FGR: Cruise control – FGB: Road speed limiter The switch is a vehicle management computer input component. The vehicle management computer transmits the driver's request to the EDC control unit via the engine CAN data bus. Note: This switch is not required in vehicles with multi-function steering wheel (A943) because the cruise control/road speed limiter functions are provided by a button that is integrated into the multi-function steering wheel. This button is also used to switch ACC on and off. ACC function – Cruise control/road speed limiter switch (S284) is deactivated. – Continuous brake switch (S479) is activated. Internal circuit

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DEVICE DESCRIPTION Technical data: Operating voltage:

16 - 32 V

Nominal voltage:

24 V

Test voltage:

27.6 V

Resistor R1:

2.2 kΩ

Resistor R4:

47 kΩ (location lighting)

Plug assignment

Pin

Line no.

Assignment

1

—–

2

60521

3

—–

4

60028

5-6

—–

7

31000

Ground Ground point, cab, behind instrument panel (X1642)

8

58000

Power supply, terminal 58, location lighting Fuse, instrument, switch and location lighting (F125)

not used Request, cruise control/limiter Vehicle management computer (A403 pin X2/16) not used Power supply, terminal 15 Fuse, vehicle management computer, terminal 15, switches/sensors (F583) not used

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DEVICE DESCRIPTION Continuous brake switch (S479)

Use: Vehicles without multi-function steering wheel The switch links the cruise control with the brake and intarder. The purpose of the switch is to activate or deactivate the power supply to the retarder/intarder electronics and thus to all retarder/intarder functions. Pressing the switch down activates the automatic retarder/intarder system. Activation is displayed by an LED in the switch. A connection to terminal 15 is established, which means a power supply of 24 V is provided. This is communicated to the vehicle management computer (A403). Pressing the switch up deactivates the automatic retarder/intarder system. The LED in the switch is no longer lit up which indicates that the system is deactivated. The connection to terminal 15 is interrupted, which means that the power supply is no longer issued. This is communicated to the vehicle management computer (A403). ACC function – Continuous brake switch (S479) is activated. – Cruise control/road speed limiter switch (S284) is deactivated. Internal circuit

Technical data: Operating voltage:

16 - 32 V

Nominal voltage:

24 V

Test voltage:

27.6V

Resistor R1:

2.2 kΩ

Resistor R4:

47 kΩ (location lighting)

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DEVICE DESCRIPTION Plug assignment

Pin

Line no.

Assignment

1

—–

2

60610

3

—–

4

60028

5-6

—–

7

31000

Ground Ground point, cab, behind instrument panel (X1642)

8

58000

Power supply, terminal 58, location lighting Fuse, instrument, switch and location lighting (F125)

not used Request for intelligent brake function or coupling Vehicle management computer (A403 pin X1/16) not used Power supply, terminal 15 Fuse, vehicle management computer, terminal 15, switches/sensors (F583) not used

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DEVICE DESCRIPTION Stalk switch, cruise control/gearbox (A429) Use: Vehicles without multi-function steering wheel ACC is operated in the same way as cruise control using the stalk switch. It is used to control the set speed above 25 km/h.

If the stalk switch is actuated, this has the following effects on the vehicle: – (1) “SET+” Increase speed (+1 km/h) – (2) “SET-” Reduce speed (-1 km/h) – (3) Rocker switch – (4) “MEM” Using the rocker switch (3), the “MEM” (“Memory”) function (4) calls up the last stored driving speed (if ACC has already been activated before) – (5) “OFF” You temporarily deactivate the ACC system by operating the “OFF” function (5) on the rocker switch (3). The system is in the status “Ready”. The previous set speed and the nominal distance are stored to make it easier to resume these settings. Note: ACC operation is only possible if the cruise control/road speed limiter switch (S284) is not actuated but the continuous brake switch (S479) is actuated! ACC is deactivated: – after starting (after terminal 15 ON): Changeover to cruise control mode is achieved by moving the changeover ring (6) on the stalk switch inwards. – from ACC driving mode: The changeover ring (6) on the stalk switch must also be moved inwards to switch from passive or active ACC driving mode into cruise control mode. The previous set speed is stored in the memory. The speed set in ACC mode is also set for cruise control and the road speed limiter. It is not set again but is called up using the “MEM” memory function (4) on the stalk switch. CAUTION: danger of accidents! If the automatic cruise control ACC is deactivated, the driver must regulate the distance himself to be able to maintain the statutory minimum distance to the vehicle in front. All these functions and operating statuses are communicated to the vehicle management computer (A403). The signals are sent to the ACC control unit (A479) via the driveline CAN data bus. The ACC control unit uses this data to control the EDC control unit (A435), the engine brake (EVB), the intarder/retarder control unit (A144) via the vehicle management computer and it controls the EBS control unit (A402) directly. In this way, deceleration or acceleration is actively controlled along with the vehicle speed.

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DEVICE DESCRIPTION Plug assignment

Pin

Line no.

Assignment

1

31000

Ground, stalk switch Ground point, cab, behind instrument panel (X1642)

2

60608

Clock line Vehicle management computer (A403 pin X1/7)

3

60609

LED actuation Vehicle management computer (A403 pin X2/17)

4

60607

Data line Vehicle management computer (A403 pin X2/8)

5

—–

6

60028

not used Power supply to stalk switch Fuse, vehicle management computer, terminal 15, switches/sensors (F583)

Technical data: Operating voltage:

16 - 32 V

Test voltage:

27.6 V

Nominal voltage: Min. current at 16 V: Max. current at 32 V:

24 V approx. 21 mA (combination with vehicle management computer) approx. 24 mA (combination with vehicle management computer)

– Input Input resistance:

5 kΩ to 24 V 125 kΩ to ground

Switching points:

low < 4 V high > 10 V

Input capacitance:

1 nF

– Outlet Maximum input current:

100 mA

Output impedance:

5 kΩ

Output level:

low < 0.5 V (100 mA) high > 5 kΩ to 24 V

Output capacitance:

1 nF

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DEVICE DESCRIPTION Operation of the ACC system Without multi-function steering wheel

The ACC system is operated in the same way as the cruise control via the stalk switch (A429) (1). It can be used to set any desired speed above 25 km/h.

There is an additional control element, namely the ACC distance button (S550) (2) installed in the instrument panel. This allows the driver to increase or reduce the time interval from the vehicle in front. Press the button “UP” to increase the time interval (+), press the button “DOWN” to decrease the time interval (-). With multi-function steering wheel

(1-5) Menu operations

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DEVICE DESCRIPTION

(6-10) Cruise control/road speed limiter The ACC system is operated using buttons 6 to 10 on the multi-function steering wheel (A943). It can be used to set any desired speed above 25 km/h. Road speed limiter and cruise control Button 6 "+": – Switch on and store speed once ignition has been switched on – Increase speed (accelerate) and store Button 7 "-": – Switch on and store speed once ignition has been switched on – Reduce speed (decelerate) and store Button 8 "OFF": Switch off Button 9 "MEM": Switch back on with the most recently stored speed Button 10 "Preselect button": changeover between road speed limiter, cruise control and ACC After the ignition is switched on, ACC is preselected – ACC must be preselected and switched on in order to start operating – ACC is not ready for use until MAN BrakeMatic is switched on Preselect ACC (changeover) – Press button 10 "Preselect button" repeatedly until the ACC symbol appears on the display ACC distance button (S550)

There is an additional control element, namely the ACC distance button (S550) (1) installed in the instrument panel. This allows the driver to increase or reduce the time interval from the vehicle in front.

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DEVICE DESCRIPTION Continuous brake button (S1133)

In vehicles with multi-function steering wheel, ACC is active if the ignition is “ON” and the continuous brake is activated. When the ignition is switched “ON”, the continuous brake is switched on automatically. The check lamp in the continuous brake button (S1133) (1) will remain off. The cruise control/road speed limiter switch is not required because the cruise control/road speed limiter function is provided by a switch integrated in the multi-function steering wheel. This switch is also used to switch ACC on and off.

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DEVICE DESCRIPTION Calibrating the ACC distance sensor (B574) General Calibration refers to the procedure of setting the distance sensor in a dened geometrical orientation in relation to the lengthways axis of the vehicle. The ACC distance sensor must be calibrated – After modications to the running gear (springs, tyres, wheels, etc.) – After every accident – After replacing the ACC distance sensor – After replacing the bumper Exception: The ACC distance sensor with the designation AC20 – new version is frame-mounted and does not need to be recalibrated after the bumper is replaced. – Whenever you detect displacement on the bolt securing lacquer – Whenever there is no bolt securing lacquer The fault message (SPN 04573-00) in the ACC control unit is stored if a tolerance of ±0.9° is exceeded. The ACC only switches off at a value above ±0.9°, and calibration is required. Note: The distance sensor is calibrated ex works. The adjusting screws of the distance sensor are sealed with RAL 3002 (Carmine Red) bolt securing lacquer – MAN item number: 04.10139-9103. The calibration can be checked using the calibration correction value with MAN-cats® II. No calibration is allowed to be performed if this value is less than ±0.7°. In the case of vehicles with air suspension, the vehicle must be at driving height in order for the adjustment to be performed. CAUTION: Safety regulations when working with lasers are to be observed. Tools Note: In the course of technical changes/enhancements, the following tools are already documented and in use. – Adjust ACC distance sensor with HD20+LC30 (TGA/TGS/TGX) – Adjust ACC distance sensor with HD30+LC40 (TGA/TGS/TGX/P11/P12/P14/P15/P16) The LC30 Koch calibration device for the ACC sensor can be used with TGS/TGX only with the aid of an adapter (MAN item number: 80.99607-0211). SI 277102 must also be observed. The ACC distance sensor with the designation AC20 – new version is calibrated exclusively with the calibration device LC40 for ACC sensor. The designation AC20 can be found on an adhesive label on the back of the distance sensor. SI 277102 must also be observed. New order/reorder: Only HD30+LC40 can be used for a new order or reorder. In the near future, it will also be possible to use this tool to cover any technical changes/enhancements of the ACC distance sensor, for all types. The time saved in the assembly of HD30+LC40 is a signicant advantage. The calibration process has been performed on TGA, TGS and TGX vehicles.

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DEVICE DESCRIPTION LC30 Koch calibration device for ACC sensor

Use: TGA/TGS/TGX Order from the appropriate national organisation LC40 calibration device for ACC sensor

Use: TGS/TGX/P11/P12/P14/P15/P16 MAN item number: 80.99607-6042 Koch HD20 axle alignment device

Use: TGS/TGX/P11/P12/P14/P15/P16 Order from the appropriate national organisation

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DEVICE DESCRIPTION Koch HD30 axle alignment device

Use: TGS/TGX/P11/P12/P14/P15/P16 Order from the appropriate national organisation MAN-cats® II

Check and adjust ACC using MAN-cats® II.

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DEVICE DESCRIPTION Adjusting tool

A tap wrench (1) with extension (2) may be used for the adjusting screws of the distance sensor. The tool is commercially available. – Tap wrench: adjustable, size 1 – Extension: size 5.5 (outer and inner square head, identical in size)

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DEVICE DESCRIPTION Calibrating the ACC distance sensor with HD20+LC30 (TGA) – HD20 = Koch axle alignment device – LC30 = Koch calibration device for ACC sensor It is not permitted to calibrate up to a calibration correction value of +/-0.7°. Remove the panel of the distance sensor and attach adapter with laser head

The panel on the distance sensor has engaged. The panel can be removed by lifting it at the sides. This is required to attach the adapter (1) and laser head (2). Important! Please turn only the knurled handle (3) of the laser head. If the laser head is rmly attached, the knurled handle can be turned without effect. If you turn the smooth handle (4), you will damage the mirror of the distance sensor behind it. If this should be the case, replace the complete distance sensor (based on the current status). Install the HD20 axle alignment device

Mount one laser head (1) on the left and right of the rear axle respectively. Clamping arms (2) are additionally used for aluminium wheels. The xtures for the laser heads on the left and right of the rear axle are secured with four magnetic rods (3).

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DEVICE DESCRIPTION

To prevent the laser beam shining into anybody's eye, it is possible to turn the laser head in such a way that a small spirit level (1) appears when seen from above. Pressing the “ON/OFF” switch (2) causes the laser beam (3) to shine downwards. The supply voltage for the laser heads on the left and right rear axle and the distance sensor comes from a battery in each laser head respectively. Position the LC30 Koch calibration device for ACC sensor

Place the guide rails (1) centrally in front of the vehicle. Place the measuring trolley (2) on the rail and push it directly in front of the vehicle. Set up the LC30 Koch calibration device for ACC sensor/HD20 axle alignment device Note: Please observe the safety regulations when using laser equipment.

Switch on the laser heads on the left and right rear axle with the “On/Off” switch (1) and calibrate to the front in line with the scale. 74

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DEVICE DESCRIPTION

The left and right rear axle laser beams (1) shine horizontally onto the measuring scales (2) on the measuring trolley.

Undo the mounting bolt (1) on the measuring trolley. This is how you move the “rod” to the left and right in a horizontal direction until the displayed values on the scale on the left and right of the measuring trolley are identical. Then the mounting bolt (1) is retightened. A spirit level (3) is tted in the measuring trolley. Its purpose is to determine if the measuring trolley is horizontal. A target disc with system of coordinates (4) graduated in 0.1° steps is installed on the measuring trolley. This target disc can be moved in elevation and azimuth using the “rod” to take account of different construction types and tyres. Azimuth (AZOF) means the horizontal position of the distance sensor signal and elevation (ELOF) means the vertical position of the distance sensor signal. Undo the mounting bolt (2) on the measuring trolley. This moves the “rod” up and down vertically. Undo the mounting bolt (5) attached behind it. This moves the target disc with coordinate system (4) horizontally to the left and right. You move the “rod” vertically up and down and the target disc with coordinate system (4) horizontally to the left and right until the laser beam coming from the distance sensor is exactly in the horizontal and vertical zero mark of the target disc. Mounting bolts (2) and (5) are subsequently retightened. This brings the distance sensor to the optical zero point.

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DEVICE DESCRIPTION

The laser head for the distance sensor is activated by connecting the plug connectors for the laser head (1) and adapter (2) together. The laser beam from the distance sensor (3) shines horizontally onto the target disc with coordinate system that is attached to the measuring trolley. Performing calibration with MAN-cats® II

Calibration is performed in the “ACC/calibration diagnostics selection menu”. Step 1 – Optical calibration

The optical setting of the distance sensor is made correctly using the target disc. This target disc with coordinate system is a tool for setting and checking the variance between the radar axis and the optical axis. During optical calibration the target disc with coordinate system is brought to the zero point (1) directly in front of the laser head of the distance sensor. It is required that the measuring trolley is horizontal and values on the left and right scale are identical (e.g. 22 cm left/right). The zero point on the target disc can be determined by moving the “rod” horizontally or vertically.

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DEVICE DESCRIPTION

(1) Laser beam from the distance sensor to the target disc with coordinate system at the measuring trolley Step 2 – Calibration correction You must perform a calibration correction after optical calibration. The radar of the distance sensor must be correctly aligned according to the specied AZOF mirror offset and ELOF mirror offset.

Push the measuring trolley 3 m away from the front axle. Next, the measuring scales must be set to the same value again. You must undo the mounting bolt (1) to move the “rod” to the left and right in a horizontal direction until the displayed values on the scale on the left and right of the measuring trolley are identical (e.g. 22 cm left/right). Then the mounting bolt (1) is retightened. After this, use the target disc to read the value and determine the sensor variance. If variance is detected, correct the sensor following the instructions in MAN-cats® II.

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77

DEVICE DESCRIPTION

Example of MAN-cats® II screen: (1) Mirror offset AZOF......-0.2°: Variance in ° (2) Mirror offset ELOF......-0.2°: Variance in ° (3) Bolt lock, top, ELOF...…-2: Turn two “teeth” anti-clockwise (clicking) (4) Bolt lock, bottom AZOF...…-2: Turn two “teeth” anti-clockwise (clicking) (5) Calibration correction value......-0.5°: The permitted variance of -0.5° is reached after correction.

There are two setting ranges for correcting the distance sensor during calibration correction according to the instructions of MAN-cats® II. The adjusting screw at the top left (ELOF) (1) is used for vertical adjustment of the distance sensor and the adjusting screw at the bottom right (AZOF) (2) is used for horizontal adjustment of the distance sensor.

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DEVICE DESCRIPTION

The bolt at the bottom left (1) is the mounting bolt for the distance sensor.

A tap wrench (1) with extension (2) may be used for the adjusting screws of the distance sensor. – Tap wrench: adjustable, size 1 – Extension: size 5.5 (outer and inner square head, identical in size) Follow the instructions in MAN-cats® II after calibration. Locking mounting bolt/adjusting screws

Subsequently after rectifying the fault or calibrating, the adjusting screws (1) of the distance sensor are marked with RAL 3002 (Carmine Red) bolt securing lacquer – MAN item number: 04.10139-9103 – to ensure that the distance sensor was calibrated by specialist personnel. If the distance sensor is tted and removed, you must also mark the mounting bolt (2) of the distance sensor with RAL 3002 (Carmine Red) bolt securing lacquer – MAN item number: 04.10139-9103.

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79

DEVICE DESCRIPTION Fitting the distance sensor panel Finally ret the panel of the distance sensor.

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DEVICE DESCRIPTION Calibrating the ACC distance sensor with HD30+LC40 (TGA/TGS/TGX) – HD30 = Koch axle alignment device – LC40 = calibration device for ACC sensor It is not permitted to calibrate up to a calibration correction value of +/-0.7°. Depiction of HD30+LC40 HD30

LC40

Removing the distance sensor panel

Unscrew mounting bolts (1) and remove the panel.

(1) Distance sensor mirror

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81

DEVICE DESCRIPTION Install the HD30 axle alignment device

Mount laser head with retainer (1) on the left rear axle. Fasten scale (2) to the shaft.

Mount laser head with retainer (1) on the right rear axle. Fasten scale (2) to the shaft. Position the LC40 calibration device for ACC sensor

Position cross bar (1) in the centre of the vehicle. Distance: 100 cm to distance sensor.

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DEVICE DESCRIPTION

Using the adjusting screws (1), align the cross bar (2) horizontally (3).

Attach measurement unit to the measurement cross bar and switch on power magnet (1).

Align measurement unit horizontally (1).

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83

DEVICE DESCRIPTION Set up the LC40 calibration device for ACC sensor/HD30 axle alignment device Note: Please observe the safety regulations when using laser equipment. Note the sign on the measuring unit.

Left rear axle. Switch on the laser head using the switch (1) and align with the cross bar towards the front. The supply voltage for the laser head, left rear axle, comes from a battery integrated into the laser head. (2) Laser beam to the cross bar (3) Laser beam from the cross bar

Right rear axle. Switch on the laser head using the switch (1) and align with the cross bar towards the front. The supply voltage for the laser head right rear axle comes from a battery integrated into the laser head. (2) Laser beam to the cross bar (3) Laser beam from the cross bar

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DEVICE DESCRIPTION

Move cross bar in the direction of the arrow until the reection values on the scale of the left/right rear axle are identical.

Pole wheel, left rear axle .......... 5 cm

Pole wheel, right rear axle .......... 5 cm

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85

DEVICE DESCRIPTION

Switch on the measuring unit using the switch (1). The supply voltage for the measurement unit comes from a battery positioned in the measuring unit.

Move the measuring unit until the laser beam is reected by the distance sensor mirror. (2) Laser beam from the measuring unit to the distance sensor mirror. (3) Laser beam from the distance sensor mirror to the measuring unit.

Coordinate system (graduation) Azimuth (AZOF) means the horizontal position of the distance sensor signal and elevation (ELOF) means the vertical position of the distance sensor signal. (2) Laser beam from the measuring unit to the distance sensor mirror. (2) Laser beam from the distance sensor mirror to the measuring unit

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DEVICE DESCRIPTION Example: ELOF = -1.0° and AZOF = +1.0° In this example, the distance sensor must be calibrated using MAN-cats® II. Note: It is not permitted to calibrate up to a calibration correction value of +/-0.7°(3). Performing calibration with MAN-cats® II

Calibration is performed in the "ACC/calibration diagnostics selection menu". Step 1 – Optical calibration

(2) Laser beam from the measuring unit to the distance sensor mirror. The “optical” alignment of the distance sensor is performed correctly by positioning the measuring unit such that the laser beam from the measuring unit hits the distance sensor mirror. Step 2 – Calibration correction You must perform a calibration correction after optical calibration. The radar of the distance sensor must be correctly aligned according to the specied AZOF mirror offset and ELOF mirror offset.

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87

DEVICE DESCRIPTION

Example of MAN-cats® II screen: (1) Mirror offset AZOF......-0.2°: Variance in ° (2) Mirror offset ELOF......-0.2°: Variance in ° (3) Bolt lock, top, ELOF...…-2: Turn two “teeth” anti-clockwise (clicking) (4) Bolt lock, bottom AZOF...…-2: Turn two “teeth” anti-clockwise (clicking) (5) Calibration correction value......-0.5°: The permitted variance of -0.5° is reached after correction.

There are two setting ranges for correcting the distance sensor during calibration correction according to the instructions of MAN-cats® II. The adjusting screw at the bottom left (AZOF) (1) is used for horizontal adjustment of the distance sensor and the adjusting screw at the top right (ELOF) (2) is used for vertical adjustment of the distance sensor.

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DEVICE DESCRIPTION

A tap wrench (1) with extension (2) may be used for the adjusting screws of the distance sensor. – Tap wrench: adjustable, size 1 – Extension: size 5.5 (outer and inner square head, identical in size) Follow the instructions in MAN-cats® II after calibration. Locking mounting bolt/adjusting screws

Subsequently after rectifying the fault or calibrating, the adjusting screws (1) of the distance sensor are marked with RAL 3002 (Carmine Red) bolt securing lacquer – MAN item number: 04.10139-9103 – to ensure that the distance sensor was calibrated by specialist personnel. If the distance sensor is tted and removed, you must also mark the mounting bolt (2) of the distance sensor with RAL 3002 (Carmine Red) bolt securing lacquer – MAN item number: 04.10139-9103. Fitting the distance sensor panel Finally ret the panel of the distance sensor.

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89

DEVICE DESCRIPTION Monitoring with MAN-cats® II: Properties and operating statuses of the ACC can be called up in the “Monitoring” selection menu in the “ACC diagnostics selection menu”. These are dynamic values, static values and status displays of the distance sensor. These are issued after replacing the ACC control unit or the distance sensor if the ACC control unit or distance sensor are not parameterised afterwards. The vehicle identier is entered in the ACC control unit and the distance sensor by a vehicle data le or conversion data le. – “Dynamic values” The “Dynamic values” menu displays the TRM status, calibration correction value and supply voltages. – “Static values” The “Static values” menu displays the serial number, radar identication and vehicle identication. This shows a pairing between the distance sensor and the ACC control unit that is performed by a vehicle data le or conversion data le. – “Status display of the radar sensor (distance sensor)” The following points are listed in the “Monitoring status display” menu: – General status display The general operating state of the distance sensor is displayed. If the operating state is not OK, switch the ignition off and on. – Internal hardware fault The operating state of the distance sensor hardware is displayed. If the operating status indicates a malfunction, switch the ignition off and on. – Initialisation The status of the initialisation of the distance sensor is displayed. After a failed rev-up, switch the ignition off and on. – Microwave transmission If the distance sensor is adjusted, the microwave transmission is issued. If a new distance sensor has been installed or the calibration has been cancelled, a new calibration process must be carried out. – Antenna status The yaw rate sensor signal detects the current direction of the road and allocates vehicles to the lanes. Radar beams are reected by vehicles in front and subsequently evaluated. If the distance sensor does not receive the reected radar beams, i.e. if the antenna status is blocked, the panel must be cleaned. – Misalignment The status of the alignment of the distance sensor is displayed. If the orientation is not OK, then the distance sensor is misaligned. The distance sensor must be realigned. – Malfunction due to interference frequency In this case, the function of the distance sensor is disrupted by an interference frequency. This may be external signals, for example. A test is to be performed, in order to establish where the signals occur. – TRM excessive temperature The status of the sender/receiver unit of the distance sensor is displayed. This relates to an internal value of the ACC control unit. – TRM undertemperature The status of the sender/receiver unit of the distance sensor is displayed. This relates to an internal value of the ACC control unit. – PCB excessive temperature The status of the printed circuit board of the distance sensor is displayed. This relates to an internal value of the ACC control unit. – 12 V current supply overvoltage The status of the 12 V power supply of the distance sensor is displayed. If there is an overvoltage, check the 12 V power supply of the voltage converter – see also SI 191302a. – 12 V current supply undervoltage The status of the 12 V power supply of the distance sensor is displayed. If there is an undervoltage, check the 12 V power supply of the voltage converter – see also SI 191302a. – Incorrect calibration for software version The status of the calibration for the software version of the distance sensor is displayed. If the ACC control unit and/or the distance sensor has/have been replaced, then the new ACC control unit is to be reparameterised and the distance sensor is to be recalibrated. – Calibration corrupt The status of the calibration of the distance sensor is displayed. If the calibration is not OK, the calibration of the distance sensor was cancelled. Calibration must be carried out again. – CAN bus fault 90

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DEVICE DESCRIPTION The status of the sensor CAN data bus is displayed. If the function of the sensor CAN data bus is not available, check the cables and plug connectors of the sensor CAN data bus and the ACC control unit (A479) for short-circuit or line disconnection. – Input data CAN fault The status of the sensor CAN data bus is displayed. If the function of the sensor CAN data bus is not available, check the cables and plug connectors of the sensor CAN data bus and the ACC control unit (A479) for short-circuit or line disconnection. – Left-hand trafc This information is available only when the vehicle is driving. A test drive must be performed. – Right-hand trafc This information is available only when the vehicle is driving. A test drive must be performed.

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91

DEVICE DESCRIPTION DESCRIPTION OF COMPONENTS ACC control unit (A479) Set-up

The ACC control unit communicates with the other systems via the CAN data bus. The control unit contains a printed circuit board with a multipoint connector. The electronics of the control unit are congured with integrated control circuits, microcontrollers and other electronic components. Installation location

The ACC control unit (1) is located in the control unit compartment behind the front cover on the co-driver's side.

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DEVICE DESCRIPTION Yaw rate sensor (B476) Set-up – TGA/TGS/TGX – old version

– TGA/TGS/TGX – new version

– P11/P12/P14/P15/P16

It relates to a micromechanical, combined yaw rate and lateral acceleration sensor. Installation location The illustrations below show an installation example and various installation positions for the yaw rate sensor in the TGA/TGS/TGX – old version.

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93

DEVICE DESCRIPTION

The yaw rate sensor is tted to the frame cross member near the centre of the vehicle. Different installation positions of the yaw rate sensor – FD/FDL:

(A) Direction of travel

(1) Plug connector in the direction of travel

– FFD/L:

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DEVICE DESCRIPTION

(A) Direction of travel

(1) Plug connector against the direction of travel

– FNLS/FNLLS:

(A) Direction of travel (1) Plug connector in the direction of travel

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95

DEVICE DESCRIPTION ACC distance sensor (B574) Set-up New version:

Old version:

Its detection range is 150 metres in the old version and 200 metres in the new version. The opening angle of the beam is approx. ±5.5°. This means the system detects the distance and relative speed of vehicles in front of it in the same lane. This information is sent to the ACC control unit. Installation location Old version TGA:

96

TGS/TGX:

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DEVICE DESCRIPTION New version TGS/TGX:

Note: The panel (cover) of the distance sensor must not be painted over.

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97

DEVICE DESCRIPTION Modular voltage converter (T119) Set-up

The voltage converter converts the 24 V power supply into a 12 V power supply for the ACC distance sensor and the yaw rate sensor. A cooling element is integrated into the voltage converter among other things. Installation location

This graphic shows an installation example for TGS/TGX. The voltage converter is installed on the co-driver's side below the central electrical system in the area of the A-pillar.

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DEVICE DESCRIPTION ACC distance button (S550) The button can be used for reducing or increasing the distance from the vehicle driving in front. Set-up – TGA

The button contains an LED for night lighting. – TGS/TGX/P11/P12/P14/P15/P16

After the ignition is switched on, distance setting 3 is always set. Installation location – TGA

The button (1) is located in the instrument panel, next to the combined instrument. T 39

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99

DEVICE DESCRIPTION – TGS/TGX

The button (1) is located in the instrument panel, next to the combined instrument.

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DEVICE DESCRIPTION Stalk switch, cruise control/gearbox (A429) Set-up

The ACC is operated using the stalk switch in the same way as cruise control. The stalk switch has a total of 7 shift functions and contains an LED for the cruise control and road speed limiter. Installation location

The stalk switch (1) is located on the right-hand side of the steering column.

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101

DEVICE DESCRIPTION Multi-function steering wheel (A943) Set-up

(1-5) Vehicle menu

(6-10) Road speed limiter and cruise control

Installation location – TGS/TGX

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DEVICE DESCRIPTION DIAGNOSTICS General Most control units that can be tested using MAN-cats® are connected with diagnostic socket X200 pin 3 via a communication line. The diagnostic system stimulates a specic control unit via the communication line. The control unit responds and transmits the faults stored in its diagnostic memory via the communication line in digital code. “KWP-on-CAN” control units such as ECAS2 and EBS5 do not have a communication line. Control units with KWP-on-CAN diagnosis are stimulated by the vehicle management computer communication line. The vehicle management computer opens a gateway to the control unit in question via the CAN. System structure of communication lines TGA

(A143) Electronically controlled air suspension (ECAS); note – ECAS2 has KWP-on-CAN diagnostics (A266) Converter-clutch unit/retarder control unit (A302) Central computer 2 (A312) Customer-specic control module (A330) TipMatic gearbox control (A402) Electronic brake system (EBS); note – EBS5 has KWP-on-CAN diagnostics T 39

(A403) (A407) (A435) (A451) (A452) (A474) (A479) (A483) (A486)

2nd edition

Vehicle management computer Combined instrument Electronic diesel injection Door control module, driver's side Door control module, co-driver's side Air-conditioning system ACC control unit Auxiliary air heater Airbag control unit 103

DEVICE DESCRIPTION (A494) Auxiliary water heater (A626) Hydrostatic front-wheel drive control unit (A688) Additional vehicle computer (only in heavy-duty semitrailer tractor) (A713) Control unit in distributor unit (air-conditioning system with auxiliary air conditioning system)

(A . . .) Other systems can be networked (X200) Diagnostic socket (X2544) 21-pin potential distributor, communication line

TGS/TGX

(A144) Retarder/intarder control unit (A250) Control unit, air-conditioning system /auxiliary air conditioning system (A266) Converter-clutch unit/retarder control unit (A302) Central computer 2 (A312) Customer-specic control module (A330) TipMatic gearbox control (A384) Control unit, RAS-EC (A402) Electronic brake system (EBS); note – EBS5 has KWP-on-CAN diagnostics (A403) Vehicle management computer 104

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(A407) (A435) (A451) (A452) (A479) (A483) (A494) (A626) (A688)

Combined instrument Electronic diesel injection Door control module, driver's side Door control module, co-driver's side ACC control unit Auxiliary air heater Auxiliary water heater Hydrostatic front-wheel drive control unit Additional vehicle computer (only in heavy-duty semitrailer tractor) (A . . . ) Other systems can be networked 2nd edition

DEVICE DESCRIPTION (X200) Diagnostic socket, 16-pin (X2544) 21-pin potential distributor, communication line

(16202) Diagnostic communication line

Bus/coach with TEPS

(A143) Electronically controlled air suspension (ECAS). Note: ECAS2 has KWP-on-CAN diagnostics (A144) Retarder/intarder control unit (A302) Central on-board computer 2 (A312) Customer-specic control module (A330) TipMatic gearbox control (A354) Control unit, retarder module (A402) Electronic brake system

(A403) (A407) (A435) (A736) (A . . .) (X200) (X2544)

Vehicle management computer Combined instrument Electronic diesel injection Control unit, gearbox, ZF Other systems can be networked Diagnostic socket 21-pin potential distributor, communication line

Diagnostic socket, 12-pin (X200) The SPN diagnostic codes can be read out from the diagnostic memory of various control units using MAN-cats® II (connection on diagnostic socket X200). The results are displayed on the MAN-cats® II display. View of socket, cable side

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DEVICE DESCRIPTION

(A) Arrow in middle points to pin 1 Plug assignment Diagnostic socket X200

Address

Terminal

Line

Central electrical system pin

Pin

Function

1

Option: HD-OBD CAN High

not used

2

Option: HD-OBD CAN Low

not used

4

Communication line KWP 2000

16202

9

Negative potential

31

31000

Ground point, central electrical system, X1644 via X1829

10

Power supply

30

30009

via X1535 to fuse F412/10 A

A2/11

11

Power supply

15

16000

via X1833 to fuse F376/10 A

F/3

12

Alternator signal

W

59101

Alternator G102 pin 1

from

via

X2544 to the control units

Diagnostic socket HD-OBD (X200) The 16-pin diagnostic socket HD-OBD according to ISO 15031-3 replaces the former 12-pin MAN diagnostic socket. HD-OBD stands for Heavy Duty On-Board Diagnosis. Heavy duty in this case refers to heavy commercial vehicles. In future, this OBD standardisation will make it possible for the rst time for almost all vehicles worldwide to have a uniform diagnostic system for exhaust-relevant components.

Plug assignment table

106

Pin

Line

1

59101

2

—-

3

16202

Function Speed signal, alternator, terminal W not used Communication line

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DEVICE DESCRIPTION

4

31000

5

—-

not used

6

185

HD-OBD-CAN High

7

—-

not used

8

16000

9 - 13

—-

not used

14

186

HD-OBD-CAN Low

15

—-

not used

16

30009

Ground terminal 31

Power supply, terminal 15

Power supply, terminal 30

Installation locations of the diagnostic socket (X200), TGA Old version

The old installation location of the 12-pin diagnostic socket X200 (1) is on the back of the central electrical system. New version

The new installation location of the diagnostic socket X200, 12-pin (1) is behind a cover below the cup holder on the co-driver's side.

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107

DEVICE DESCRIPTION Installation location of the diagnostic socket HD-OBD (X200) in TGA

The installation location of the diagnostic socket HD-OBD X200, 16-pin (1) is located behind a cover below the cup holder on the co-driver's side and replaces the previous 12-pin diagnostic socket. Installation location of the diagnostic socket HD-OBD (X200) in TGS/TGX

The diagnostic socket HD-OBD X200, 16-pin (1) is located on the co-driver's side under a cover, which has to be folded down. The central electrical system is located above the socket. Bus/coach with TEPS (shared data exchange)

The diagnostic sockets X200 (1) and X3090 (2) are located on the driver's partition in front of the 1st row of seats on the left-hand side.

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DEVICE DESCRIPTION Main functions of the diagnostics – Fault detection – Fault analysis Occurrence Meaning Identication Fault type (static, sporadic, etc.) – Fault storage – Simulation for troubleshooting Malfunction indicators The electronic control unit has self-diagnosis functions for all outputs and various inputs. The faults at the inputs and outputs, as well as internal faults, are detected, analysed and stored in the control unit diagnostic memory. The faults are also indicated on the combined instrument display and/or by the central warning lamp (H111) in conjunction with the check lamp of the corresponding system. In the case of STOP commands, the word STOP also appears on the display and the central warning lamp (H111) ashes RED at 1-second intervals. The central warning lamp (H111) lights up: – YELLOW to indicate either a function or a warning – RED to indicate a fault Red always has priority over yellow. Functions or warnings (YELLOW) are always overridden by malfunctions (RED). In the event of a CAN failure (combined instrument – central on-board computer), the central warning lamp (H111) lights up RED. All current malfunction indicators are available when the ignition is switched “ON” (terminal 15), irrespective of the vehicle status. The faults diagnosed and stored in the control unit may involve different risks. Therefore, each individual fault is assigned a priority. Priorities of the displays (TGA) The display cannot show all the information at once. It therefore shows information according to priorities. Lower-priority information can be overwritten by higher-priority information. Pieces of information that have the same priority are shown alternately if there is not enough room on the display. Diagnosis requires priorities 1 – 5. Some function indicators have the same or a higher priority than fault indicators. In other words, a function indicator (YELLOW) can have the same priority as a RED fault or even a STOP fault. If the display area is already full and additional function indicators and fault indicators with the same priority occur, the function indicator is given priority.

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DEVICE DESCRIPTION Priorities, indicator/diagnosis (TGA) Diagnostics, priority

Indicator meaning

Colour of central warning lamp (H111)

Diagnostics, meaning Driveability or safety is endangered (STOP fault, RED)

1

Indicator critical to safety

Flashing RED

2

Indicator critical to functioning

Illuminated RED

3

Indicator not necessary for purely normal driving operation

Illuminated YELLOW

Information before starting to drive or driving safety not restricted (YELLOW fault)

4

—

—

No effect on driveability

5

Information about fault whilst vehicle in motion

Illuminated YELLOW

Warning (YELLOW fault)

Driving information with recommended action, check (RED fault)

The display only ever shows one fault at a time. Structure of the fault texts in the diagnostic message There are 2 lines of 16 characters available for the fault texts in the diagnostic message. The fault text message structure always includes: – Fault location/fault designation – Fault information/recommended action There are 2 types of fault text messages: – Global fault text messages – Specic fault text messages Global fault text message In the global fault text message, only the priority and the source address from the DM1 message (diagnostic message 1) are evaluated. A general message is displayed, indicating the faulty system and the transmitted fault number. Diagnosis priority

Central warning lamp

Fault text 1234567890123456

1

Flashing RED

Sysname no. xxxxx-yy diagnosis

In conjunction with STOP symbol. Engine must be stopped!

2

Illuminated RED

Sysname no. xxxxx-yy diagnosis

Possibly workshop-relevant fault! Indicates malfunction

3

Illuminated YELLOW

Sysname no. xxxxx-yy diagnosis

Display at standstill, fault information only; no recommended action necessary

4

—

—

No display

5

Illuminated YELLOW

Sysname no. xxxxx-yy diagnosis

Display when vehicle in motion and at standstill; fault information only

Comments

– “Sysname”: Details of the faulty system from the source address of DM1 (e.g.: ACC) – “xxxxx”: Indicates the fault number from the fault location number (SPN) in the DM1 message (e.g.: ACC no. 04536) – “yy”: Indicates the fault type number (FMI) (e.g.: ACC no. 04536-03) SPN –> Suspect Parameter Number (fault location) FMI –> Failure Mode Identication (fault type)

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DEVICE DESCRIPTION Status display, FMI (Failure Mode Identication)

FMI 0 Fault not specied

FMI 6 Short-circuit to +UBat

FMI 12 Disconnection or short-circuit to +UBat

FMI 1 Too high

FMI 7 Short-circuit

FMI 13 Disconnection or short-circuit to ground Memory status

FMI 2 Too low

FMI 8 Signal faulty

FMI 3 Implausible

FMI 9 Device fault

FMI Fault stored

FMI 4 No signal available

FMI 10 Disconnection

FMI Intermittent fault

FMI 5 Short-circuit to ground

FMI 11 Loose contact

FMI Fault active and has been stored

FMI No fault

Specic fault text message In the case of the specic fault text message, the priority, SPN fault number and fault type (FMI) transmitted in the DM1 message are also evaluated. Specic action if recommended and the specic fault cause is named. The SPN fault number is not displayed in the case of specic fault text messages. Note: Several different faults can trigger the same specic fault text message.

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111

DEVICE DESCRIPTION Priority in the display/diagnostics, software versions R22 and R24 Symbol

Indicator meaning

Colour of central warning lamp (H111)

Safety

Flashing red

Threat of vehicle damage. Driving safety at risk.

Workshop

Illuminated red

Workshop visit necessary immediately. Driving safety may be at risk.

Information

Illuminated yellow

Diagnostics, meaning

Remedy the fault immediately or drive slowly to a workshop, depending on the cause of the yellow message.

For display of fault texts, see system description of combined instrument T 62. Structure of the fault texts in the diagnostic message The fault text message structure always includes: – Symbol – Text message – Check lamp – Audible signal There are 3 types of text message: – One message – Several messages – Message indicating a value One message

In the case of a single message, only the fault, system data and priority are indicated.

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DEVICE DESCRIPTION Several messages with multi-function steering wheel A943

(1) Display for several faults (2) Symbol for conrmation

(3) Symbol for scrolling (4) Symbol for at least 10 faults

If there are several faults, this can be seen by the double left edge (1). If more than 9 faults occur, this is indicated by the plus sign (4) in the status line. Several messages without multi-function steering wheel A943

The double edge indicates that there are several messages, while the two lower rectangular elds indicate the possible button functions for the buttons shown on the next graphic.

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113

DEVICE DESCRIPTION Message indicating a value

The combined message shows precisely the rear axle and side on which the tyre with insufcient pressure is located. The values allow a comparison. The deviating value has a black background.

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DEVICE DESCRIPTION SPN – diagnostic codes shown on the display, software versions R22 and R24 The display is integrated in the combined instrument (A407). All the driver and service information is displayed. View of the display

The gure above shows a fault message from the ACC system. If you now call up the diagnostics in the menu, you will see the SPN diagnostic code on the display, as shown by the next illustration.

The fault is active and has a priority of 5. The SPN is 02201 and the FMI (Failure Mode Identication) is 3 (specic fault text message).

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115

DEVICE DESCRIPTION Break box After having tted the stalk switch for cruise control/gearbox (A429), cruise control/road speed limiter switch (S284), continuous brake switch (S479), continuous brake button (S1133) and multi-function steering wheel (A943), the vehicle management computer checks the function of the components that require a connection to ACC using a break box. Example of a break box connection: Components:

Components connected:

Position 1

Designation

Item number

Break box with measuring jumpers

80.99641-6027

The set of 69-pin cable arms for the vehicle management computer and ECAS consists of items 2, 3 and 4, which are described below. The components included in the set can also be ordered individually at a later date.

116

80.99641-6023

2

Cover plate for break box, 69-pin

80.99641-0068

3

Cable arms, 69-pin (pin) for connection to the vehicle cable harness

80.99641-0050

4

Cable arms, 69-pin (socket) for connection to the control unit

80.99641-0049

5

Connection to vehicle cable harness “A403 - X1: white”

6

Connection to vehicle cable harness “A403 - X2: dark grey”

7

Connection to vehicle cable harness “A403 - X3: yellow”

8

Connection to vehicle cable harness “A403 - X4: light grey”

9

Connection to vehicle management computer “A403 - X4: light grey”

10

Connection to vehicle management computer “A403 - X3: violet”

T 39 2nd edition

DEVICE DESCRIPTION

11

Connection to vehicle management computer “A403 - X2: dark grey”

12

Connection to vehicle management computer “A403 - X1: white”

Connecting the break box: – Secure the vehicle to prevent it from rolling away unintentionally (parking brake, wheel chocks). – Switch off the engine and the ignition. – Check that the vehicle management computer is protected by the specied 10 A or 7.5 A fuses: F371 – power supply, vehicle management computer, terminal 30 (battery) and F372 – power supply, vehicle management computer, terminal 15 (ignition). – Disconnect the vehicle management computer. – Connect the break box between the vehicle management computer and the vehicle cable harness. Use the test step list to check the components or functions of the vehicle management computer that are required in conjunction with ACC using the break box and a multi-function measuring device (multimeter). Square-wave signals are measured with a Fluke ScopeMeter 123. Multi-function measuring device – multimeter Voltage and resistance values are determined using the multi-function measuring device (multimeter).

MAN item number: 08.78020-9021

T 39 2nd edition

117

DEVICE DESCRIPTION Fluke ScopeMeter 123 Square-wave signals are monitored using the Fluke ScopeMeter 123.

MAN item number: 08.78023-0000 Troubleshooting program The following troubleshooting program contains the faults that can be detected by the diagnostic memory. The sequence of tests corresponds to the numerical succession of diagnostic codes (SPNs), irrespective of the evaluation of the fault. During the receipt check on a vehicle, always read out the entire diagnostic memory and document all stored errors (MAN-cats® shortcut CTRL+F11). This is important because cables and/or components have to be disconnected during troubleshooting and this means the corresponding fault messages may be set and saved. Consequently, the diagnostic memory should always be deleted after intermediate inspections. If parts are exchanged, send a printout from MAN-cats® verifying the fault together with the returned part in order to claim back the costs. (The printout is an extract from the diagnostic memory, see above.) Other procedures are only permitted subject to consultation with the Service Department in Munich! Likewise, control units may only be exchanged under warranty subject to consultation with the Service Department in Munich. Repeat the check and delete the diagnostic memory after rectifying the fault and checking the repair work. The diagnostic memory should always be deleted using MAN-cats® Always delete the diagnostic memory and observe the fault before replacing any components or control units. If there are several diagnostic memory entries, always take test information into account rst that does not require any components or control units to be replaced. Always switch off the 118

T 39 2nd edition

DEVICE DESCRIPTION ignition before carrying out the repair and replacing components or control units. Failure to switch off the ignition will lead to diagnostic memory entries (SPNs) in the various electronic control units. Always carry out the "Check cables" step as follows: – Disconnection or contact resistance (e.g. due to widened sockets, pushed back plugs/sockets or oxidised plug connectors) – Short-circuit to negative – Short-circuit to positive – Short-circuit to adjacent lines – Loose contacts – Water or moisture in the cable harness Cable harnesses may be damaged even though the corrugated tube appears undamaged from the outside! Break the connection to the control unit before measuring resistance values. Refer to vehicle-specic circuit diagrams! Resistance measurement – Ignition “OFF” – The break box is connected between the vehicle management computer and the vehicle. – All jumpers must be closed in the break box. The jumper at which the value is being measured must be open. Voltage measurement – The break box is connected between the vehicle management computer and the vehicle. – Ignition “ON” – All jumpers must be closed in the break box. Measurement for the "cruise control/gearbox" stalk switch is also performed with the jumper open. Voltage is measured with the engine running and the vehicle stationary.

T 39 2nd edition

119

DEVICE DESCRIPTION SPN – diagnostic code description This section presents the diagnostic codes that are shown on the combined instrument display or MAN-cats® screen in the event of a fault. The fault causes and responses are documented for the listed diagnostic code descriptions. SPN - Suspect Parameter Number – fault location Note: See test step list for test step The SPN diagnostic codes in the range from 04432 up to and including 04499 are not stored in the diagnostic memory of the ACC control unit (A479). These diagnostic codes dene shut-off conditions of the ACC. ACC depends on other control units being set correctly (parameterisation). This means it is possible for an ACC fault to be signalled although the fault that occurs has not been caused by ACC, only detected by ACC. The SPN diagnostic codes in the range from 04500 up to and including 04585 are stored in the diagnostic memory of the ACC control unit (A479). These diagnostic codes dene the faults that have occurred or been detected in the ACC. SPN

SPN-Plain text Description

04432

Cruise control switch (sleeve) operated The signal comes from the cruise control/road speed limiter switch (S284) in connection with the stalk switch for cruise control/gearbox (A429). "Sleeve" is the changeover ring of the stalk switch for cruise control/gearbox. Move the changeover ring on the stalk switch to the inside if you would like to go from ACC driving mode to cruise control mode. Fault reaction: ACC switches off. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Fault rectication: No fault rectication required. ACC must be reactivated by the driver. If this fault is frequently reported, the driver must be informed about operation/functions of the ACC. Information is documented in the Operator's Manual.

04433

Cruise control switch “Off” actuated Signal coming from the cruise control/road speed limiter switch (S284) or the preselect button "FGB, FGR and ACC" ("road speed limiter, cruise control and Adaptive Cruise Control") on the multi-function steering wheel. Fault reaction: ACC switches off. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Fault rectication: No fault rectication required. ACC must be reactivated by the driver. If this fault is frequently reported, the driver must be informed about operation/functions of the ACC. Information is documented in the Operator's Manual.

04434

Road speed limiter mode/road speed limiter switch is on Signal coming from the cruise control/road speed limiter switch (S284) or the preselect button "FGB, FGR and ACC" ("road speed limiter, cruise control and Adaptive Cruise Control") on the multi-function steering wheel. Fault reaction: ACC switches off. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Fault rectication: No fault rectication required. ACC must be reactivated by the driver. If this fault is frequently reported, the driver must be informed about operation/functions of the ACC. Information is documented in the Operator's Manual.

120

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2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04435

Parking brake not released/parking brake applied The signal is sent from the EBS control unit (A402). Fault reaction: ACC switches off. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Fault rectication: No fault rectication required. ACC must be reactivated by the driver. If this fault is frequently reported, the driver must be informed about operation/functions of the ACC. Information is documented in the Operator's Manual.

04436

ABS faulty/invalid The signal is sent from the EBS control unit (A402). Fault reaction: ACC switches off. Fault cause: ABS not responding and/or faulty Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04437

EBS faulty/invalid The signal is sent from the EBS control unit (A402). Fault reaction: ACC switches off. Fault cause: EBS not responding and/or faulty or EBS 5/4 tted. EBS 4 is standard. EBS 5/4 disables braking by the ACC when trailers with no ABS are used. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04438

Footbrake activated The signal is sent from the accelerator unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Fault rectication: No fault rectication required. ACC must be reactivated by the driver. If this fault is frequently reported, the driver must be informed about operation/functions of the ACC. Information is documented in the Operator's Manual.

04439

Continuous brake lever operated The signal is sent from retarder/intarder. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Fault rectication: No fault rectication required. ACC must be reactivated by the driver. If this fault is frequently reported, the driver must be informed about operation/functions of the ACC. Information is documented in the Operator's Manual.

04440

Continuous brakes “Off” The signal is sent from the continuous brake switch (S479) or the continuous brake button (S1133). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Fault rectication: No fault rectication required. ACC must be reactivated by the driver. If this fault is frequently reported, the driver must be informed about operation/functions of the ACC. Information is documented in the Operator's Manual.

04441

ASR intervention The signal is sent from the EBS control unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: ASR intervention Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. T 39

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121

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04442

ABS intervention The signal is sent from the EBS control unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: ABS intervention Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04443

ESP intervention The signal is sent from the EBS control unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: ESP intervention Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04444

ACC has activated EBS for too long/brake temperature The signal is sent from the EBS control unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Fault rectication: Adapt driving style to allow the brakes to cool down and to be able to reactivate ACC.

04445

Engine speed too low The signal is sent from the EDC control unit (A435). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Fault rectication: Increase speed, observe shifting states.

04446

Delay too long The signal is sent from the EBS control unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Excessive ACC system deceleration, EBS mass estimate possibly incorrect. Fault rectication: Driving longer distances. Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04447

No/invalid driving speed The signal is sent from the vehicle management computer (A403) or the central on-board computer 2 (A302) or the tachograph (A408). Fault reaction: Controlled ACC deactivation is performed. Fault cause: No driving speed available on the driveline CAN data bus. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04448

No EBS intervention possible The signal is sent from the EBS control unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: EBS does not permit ACC intervention Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04449

EBS status check The signal is sent from the EBS control unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: EBS status implausible Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

122

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DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04450

ESP faulty The signal is sent from the EBS control unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: ESP failed/ESP not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04451

No brake pedal/invalid CAN message EBC1. Brake pedal EBC1 = Electronic Brake Controller 1. EBC1 is the name of the message. It is sent from the EBS control unit (A402) and supplies information on the brake pedal. Fault reaction: Controlled ACC deactivation is performed. Fault cause: If the EBC1 message is not OK or has not been received within a time period that can be parameterised, a timeout is set. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04452

Continuous brake lever faulty/invalid CAN message ERC1X.Continuous brake lever In vehicles without multi-function steering wheel, the continuous brake lever is the continuous braking momentary switch (A437), in vehicles with multi-function steering wheel, this is the stalk switch for retarder/gearbox (A942). The signal is sent from the stalk switch that the driver uses in normal mode to create continuous brake torque. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Continuous brake rocker switch (A437)/stalk switch for retarder/gearbox (A942) not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04453

No engine/invalid CAN message EEC1.Torque EEC1 = Electronic Engine Controller 1. EEC1 is the name of the message that is sent from the EDC control unit or the vehicle management computer (A403) and supplies information about engine torque. Fault reaction: Controlled ACC deactivation is performed. Fault cause: If the EEC1 message is not OK or hasn't been received within a time period that can be parameterised, a timeout is set. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04454

Engine intervention not by ACC, driver, gearbox, road speed limiter, max. road speed limiter, maximum-speed governor (EDR) or brake. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Intervention by unknown control unit. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04455

No engine speed/invalid CAN message EEC1.Engine speed EEC1 = Electronic Engine Controller 1. EEC1 is the name of the message that is sent from EDC or the vehicle management computer (A403) and supplies information about engine speed. Fault reaction: Controlled ACC deactivation is performed. Fault cause: If the EEC1 message is not OK or hasn't been received within a time period that can be parameterised, a timeout is set. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

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2nd edition

123

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04456

No accelerator/invalid CAN message EEC2.Accelerator EEC2 = Electronic Engine Controller 2. EEC2 is the name of the message sent by the EDC or vehicle management computer (A403). The message contains signals from the accelerator, kick down or the load in force at the current speed. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Accelerator invalid or EEC2 message not received. Vehicle management computer failed/vehicle management computer not responding or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04457

No accelerator/invalid CAN message EEC2.Idling speed switch EEC2 = Electronic Engine Controller 2. EEC2 is the name of the message sent by the EDC or vehicle management computer (A403). The message contains signals from the accelerator, kick down or the load in force at the current speed. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Accelerator programming incorrect or not performed Fault rectication: Program accelerator. Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04458

No RX/invalid CAN message ERC1_RX.Torques (engine brake) ERC1_RX is the message that is only sent if there is an engine brake (EVB) installed (parameterise vehicle management computer). Fault reaction: Controlled ACC deactivation is performed. Fault cause: EVB not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04459

No RD/invalid CAN message ERC1_RD.Torques (secondary retarder) ERC1_RD is the message that is only sent if there is a secondary retarder installed (parameterise vehicle management computer). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Intarder not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04460

No RE/invalid CAN message ERC1_RE.Torques (primary retarder) ERC1_RE is the message that is only sent if there is a primary retarder installed (parameterise vehicle management computer). Fault reaction: Controlled ACC deactivation is performed. Fault cause: PriTarder not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04461

Retarder intervention fault The signal is sent from the intarder/PriTarder or the vehicle management computer (A403). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Intarder, PriTarder or vehicle management computer not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04462

No ground The signal is sent from the EBS control unit (A402) or the vehicle management computer (A403). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Ground calculation incorrect Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

124

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DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04463

Display faulty The signal is sent from the combined instrument (A407). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Display not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04464

No cruise control switch/invalid CAN message CCVS.Cruise control switch CCVS = Cruise Control/Vehicle Speed. It includes information about the status of the cruise control/road speed limiter (S284) switch and the status of the preselect button "FGB, FGR and ACC" (road speed limiter, cruise control and Adaptive Cruise Control) on a multi-function steering wheel. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Cruise control switch not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check cruise control switch for functionality, check cables and plug connectors.

04465

Cruise control active in ACC mode/invalid CAN message CCVS.enable == cruise control CCVS = Cruise Control/Vehicle Speed. It includes information about the status of the cruise control/road speed limiter (S284) switch and the status of the preselect button "FGB, FGR and ACC" (road speed limiter, cruise control and Adaptive Cruise Control) on a multi-function steering wheel. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Cruise control switch not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check cruise control switch for functionality, check cables and plug connectors.

04466

No road speed limiter switch/invalid CAN message CCVS.Road speed limiter switch CCVS = Cruise Control/Vehicle Speed. It includes information about the status of the cruise control/road speed limiter (S284) switch and the status of the preselect button "FGB, FGR and ACC" (road speed limiter, cruise control and Adaptive Cruise Control) on a multi-function steering wheel. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Road speed limiter switch not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check road speed limiter switch for functionality, check cables and plug connectors.

04467

No continuous brakes OFF/invalid CAN message CCVS.IntelBrakeCoupl. CCVS = Cruise Control/Vehicle Speed. Here, it includes information on intelligent brake coupling – the status of the continuous brake switch (S479) and the continuous brake button (S1133). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Switch or button for Brakematic not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check Brakematic switch/button for functionality, check cables and plug connectors.

04468

No cruise control lever/invalid CAN message CCVS.Off switch or CCVS.Lever CCVS = Cruise Control/Vehicle Speed. Here, it includes information on the status of the stalk switch for cruise control/gearbox (A429). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Stalk switch for cruise control/gearbox not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check stalk switch for cruise control/gearbox for functionality, check cables and plug connectors.

T 39

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125

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04469

No range selector switch/invalid CAN message AUX1_ZBR.Switch The message is called AUX1_ZBR and it includes information about the status of the ACC distance button (S550). Fault reaction: Controlled ACC deactivation is performed. Fault cause: ACC distance button not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check ACC distance button for functionality, check cables and plug connectors. Test steps: Measure voltage: Power supply for location lighting; ACC distance button – pin 8 (+) and pin 7 (-): ~= 16 - 32 V (UBat) Reduce power supply for distance; ACC distance button – pin 3 (+) and pin 2 (-) on vehicles without multi-function steering wheel; pin 3 (+) and pin 5 (-) on vehicles with multi-function steering wheel: press button down, connection to terminal 15: ~= 16 - 32 V (UBat) Increase power supply for distance; ACC distance button – pin 4 (+) and pin 5 (-) on vehicles without multi-function steering wheel; pin 4 (+) and pin 2 (-) on vehicles with multi-function steering wheel: press button up, connection to ground: 0 V. Replace the ACC distance button (S550) if the cause of the fault is not clear.

04470

Driveline fault/invalid CAN message ETC1.ShiftInProcess or ETC1.DrivelineEngaged ETC1 = Electronic Transmission Control 1. This message is sent by the vehicle management computer (A403) only when there is a manually operated gearbox. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Fault in driveline CAN data bus Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04471

Clutch fault/invalid CAN message CCVS.Clutch CCVS = Cruise Control/Vehicle Speed. It includes information about the clutch. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Fault in driveline CAN data bus Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04472

Clutch travel invalid The signal is sent from the clutch travel sensor. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Clutch pedal travel programmed incorrectly or not at all Fault rectication: Program clutch travel. Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04473

Speed irregularities between EEC1.Engine speed and TCO1.Speed EEC1 = Electronic Engine Controller 1. The number 1 denes the content (engine speed) of the message. TCO1 = Tachograph. The message contains speed information and a malfunction warning ag. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Speed sensors supply contradicting signals. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

126

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DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04474

Valid ETC2.Ratio markedly different from valid speed ratio ETC2 = Electronic Transmission Control 2. The number 2 denes the content (gear display and shift arrows) of the message. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Axle ratio deviates considerably. The message from the vehicle management computer (A403) is not received. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04475

No TCO speed/invalid CAN message TCO.Speed TCO = Tachograph. The message contains speed information and a malfunction warning ag. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Tachograph not responding and/or faulty. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04476

No wheel speed/invalid CAN message EBC2.Speed EBC2 = Wheel speed information. The number 2 denes the content (wheel speed) of the message. The signal is sent from the EBS control unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: EBS wheel speed incorrect Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04477

Engine speed too high The signal is sent from the EDC control unit (A435). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Fault rectication: ACC is reactivated by reducing engine speed. If this fault is frequently reported, the driver must be informed about operation/functions of the ACC. Information is documented in the Operator's Manual.

04478

No gear or clutch disengaged/open driveline for about 10 sec. The signal is sent from the vehicle management computer (A403). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Fault rectication: ACC is reactivated by engaging the clutch or a gear. If this fault is frequently reported, the driver must be informed about operation/functions of the ACC. Information is documented in the Operator's Manual.

04479

Speed too slow Fault reaction: Controlled ACC deactivation is performed. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Driving speed < 25 km/h Fault rectication: ACC is reactivated by increasing driving speed. If this fault is frequently reported, the driver must be informed about operation/functions of the ACC. Information is documented in the Operator's Manual.

04480

Speed too fast Fault reaction: Controlled ACC deactivation is performed. Fault cause: Operator error by the driver. No realistic shifting and functional states, caused by an operator error by the driver. Fault rectication: ACC is reactivated by adapting driving speed. If this fault is frequently reported, the driver must be informed about operation/functions of the ACC. Information is documented in the Operator's Manual.

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127

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04481

Bend too tight/valid bending too great The signal is sent from the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Corner radius too small. Fault rectication: No fault rectication required. ACC must be reactivated by the driver.

04482

No yaw rate/invalid yaw rate The signal is sent from the yaw rate sensor (B476). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Yaw rate sensor supplying invalid yaw rate. Fault rectication: Check the yaw rate sensor for functionality and its installation position; the arrow on an adhesive label attached to the side of the yaw rate sensor must always point along the vehicle, never across the vehicle. Test step: Measure voltage: Power supply for yaw rate sensor; yaw rate sensor – pin 1 (+) and pin 2 (-): ~= 12 V. Replace the yaw rate sensor (B476) if the cause of the fault is not clear.

04483

No lateral acceleration/invalid lateral acceleration The signal is sent from the yaw rate sensor (B476). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Yaw rate sensor supplying invalid lateral acceleration. Fault rectication: Check the yaw rate sensor for functionality and its installation position; the arrow on an adhesive label attached to the side of the yaw rate sensor must always point along the vehicle, never across the vehicle. Test step: Measure voltage: Power supply for yaw rate sensor; yaw rate sensor – pin 1 (+) and pin 2 (-): ~= 12 V. Replace the yaw rate sensor (B476) if the cause of the fault is not clear.

04484

Radar still in initialisation mode (after ACC initialisation mode) The signal is sent from the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: ACC distance sensor still in initialisation mode when activated. Fault rectication: Ignition "OFF" and ignition "ON" again; check 12 V power supply of the ACC distance sensor; check cables and plug connectors Test step: Measure voltage: Power supply for ACC distance sensor; ACC distance sensor – pin 1 (+) and pin 2 (-): ~= 12 V. Replace the ACC distance sensor (B574) if the cause of the fault is not clear.

04485

Bending is detected as invalid in CAN message The signal is sent from the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Minimum curve radius not reached Fault rectication: No fault rectication required.

128

T 39

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04499

ACC control unit is still in initialisation phase The signal is sent from the ACC control unit (A479). Fault reaction: Unable to activate ACC. Fault cause: ACC control unit still in initialisation mode on activation. Fault rectication: Ignition "OFF" and ignition "ON" again; check 24 V power supply of the ACC control unit; check cables and plug connectors Test steps: Measure voltage: Power supply for ACC control unit terminal 15; ACC control unit – pin X1/2 (+) and pin X1/3 (-): ~= 16 - 32 V (UBat) Power supply for ACC control unit terminal 30; ACC control unit – pin X1/1 (+) and pin X1/3 (-): ~= 16 - 32 V (UBat)

04500

Internal system error, Trap NMI The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04501

Internal system error, Stack overow The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04502

Internal system error, Stack underow The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04503

Internal system error, Trap ILLBUS The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04504

Internal system error, Trap ILLINA The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04505

Internal system error, Trap ILLOPA The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04506

Internal system error, Trap PRTFLT The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

T 39

2nd edition

129

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04507

Internal system error, Trap UNDOPC The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04508

Internal system error, Trap PECC5 The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04509

Internal system error, Trap PECC6 The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04510

Internal system error, Trap PECC7 The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04511

Internal RAM faulty/memory test on switch-on The signal is sent from the ACC control unit (A479). Fault reaction: Unable to activate ACC. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04512

External RAM faulty/address line test on switch-on The signal is sent from the ACC control unit (A479). Fault reaction: Unable to activate ACC. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04513

External RAM faulty/memory test on switch-on The signal is sent from the ACC control unit (A479). Fault reaction: Unable to activate ACC. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04514

Flash faulty/ash checksum test on switch-on The signal is sent from the ACC control unit (A479). Fault reaction: Unable to activate ACC. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04515

External watchdog/test of function of the external watchdog on switch-on The signal is sent from the ACC control unit (A479). Fault reaction: Unable to activate ACC. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

130

T 39

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04516

Program runtime exceeded The signal is sent from the ACC control unit (A479). Fault reaction: Unable to activate ACC. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04517

HighLevelTask too long/runtime monitoring The signal is sent from the ACC control unit (A479). Fault reaction: Unable to activate ACC. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04518

LowLevelTask too long/runtime monitoring The signal is sent from the ACC control unit (A479). Fault reaction: Unable to activate ACC. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04519

Application task too long The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace ACC control unit

04520

Supply voltage (tl.15) too low The signal is sent from the ACC control unit (A479). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Supply voltage below 18 V for 5 seconds; the fault may be caused by briey disconnecting, switching off or removing the fuse for the ACC control unit Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and subsequently delete the diagnostic memory. If the fault is still present: Check the power supply; wait at least 20 seconds before the ACC control unit can be disconnected Test step: Measure voltage: Power supply for ACC control unit terminal 15; ACC control unit – pin X1/2 (+) and pin X1/3 (-): ~= 16 - 32 V (UBat)

04521

Tl. 30 voltage too low The signal is sent from the ACC control unit (A479). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Terminal 30 voltage below 8 V for 1 second; the fault occurs by briey disconnecting, switching off or removing the fuse of the ACC control unit. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and subsequently delete the diagnostic memory. If the fault is still present: Check the power supply; wait at least 20 seconds before the ACC control unit can be disconnected Test step: Measure voltage: Power supply for ACC control unit terminal 30; ACC control unit – pin X1/1 (+) and pin X1/3 (-): ~= 16 - 32 V (UBat)

T 39

2nd edition

131

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04522

Relay faulty, no terminal 30. The signal is sent from the ACC control unit (A479). Fault reaction: Unable to activate ACC. Fault cause: Check the relay function by switching on and off and measuring voltages; the fault may be caused by briey disconnecting, switching off or removing the fuse of the ACC control unit. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and subsequently delete the diagnostic memory. If the fault is still present: Check terminal 30 connection on the ACC control unit and cable harness; wait at least 20 seconds before the ACC control unit is allowed to be removed. Test step: Measure voltage: Power supply for ACC control unit terminal 30; ACC control unit – pin X1/1 (+) and pin X1/3 (-): ~= 16 - 32 V (UBat)

04523

Relay faulty, continuous terminal 30. The signal is sent from the ACC control unit (A479). Fault reaction: Unable to activate ACC. Fault cause: Check the relay function by switching on and off and measuring voltages to double-check. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and subsequently delete the diagnostic memory. If the fault is still present: check terminal 30 connection to the ACC control unit and cable harness Test step: Measure voltage: Power supply for ACC control unit terminal 30; ACC control unit – pin X1/1 (+) and pin X1/3 (-): ~= 16 - 32 V (UBat)

04524

Invalid data record/EEPROM checksum test on switch-on. The signal is sent from the ACC control unit (A479). Fault reaction: Unable to activate ACC. Fault cause: Control unit fault or incorrect parameterisation Fault rectication: Reparameterise ACC control unit and subsequently switch off terminal 15. Replace the ACC control unit if unsuccessful.

04525

Driveline CAN fault/if Bus-Off is reached and 0.5 s afterwards In the event of Bus-Off, the control unit is not taking part in CAN communication. The signal is sent from the driveline CAN data bus. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Driveline CAN data bus fault Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check the cables and plug connectors of the driveline CAN data bus for short-circuit or line disconnection. Test steps: Measure resistance: Driveline CAN data bus; ACC control unit – pin X1/14 (+) and pin X1/15 (-): approx. 60 Ω Driveline CAN data bus; vehicle management computer – pin X1/14 (+) and pin X1/15 (-): approx. 120 Ω, at approx. 0 Ω short-circuit from CAN-High to CAN-Low.

132

T 39

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04526

Driveline CAN fault/if overow occurred in CAN controller The signal is sent from the driveline CAN data bus. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Driveline CAN data bus fault Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check the cables and plug connectors of the driveline CAN data bus for short-circuit or line disconnection. Test steps: Measure resistance: Driveline CAN data bus; ACC control unit – pin X1/14 (+) and pin X1/15 (-): approx. 60 Ω Driveline CAN data bus; vehicle management computer – pin X1/14 (+) and pin X1/15 (-): approx. 120 Ω, at approx. 0 Ω short-circuit from CAN-High to CAN-Low.

04527

Cannot send TSC1-EBS/last send message has not been sent yet TSC1 = Torque Speed Control 1. The message for torque speed control is sent from the EBS control unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Driveline CAN data bus fault Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check the cables and plug connectors of the driveline CAN data bus for short-circuit or line disconnection.

04528

Cannot send TSC1-vehicle management computer/last send message has not been sent yet TSC1 = Torque Speed Control 1. The message for torque speed control is sent from the vehicle management computer (A403). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Driveline CAN data bus fault Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check the cables and plug connectors of the driveline CAN data bus for short-circuit or line disconnection.

04529

EBC1 CAN message not received EBC1 is the name of the message from the EBS control unit (A402) and contains signals related to the brake pedal and/or the ABS and ASR statuses. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of gearbox control unit/EBS Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04530

ERC1_RX CAN message not received (engine brake) ERC1_RX is the message that is only sent if there is an engine brake installed (parameterise vehicle management computer). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of vehicle management computer Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04531

ERC1_RE CAN message not received (primary retarder) ERC1_RE is the message that is only sent if there is a primary retarder installed (parameterise vehicle management computer). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of exhaust valve brake (EVB) Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

T 39

2nd edition

133

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04532

ERC1_RD CAN message not received (secondary retarder) ERC1_RD is the message that is only sent if there is a secondary retarder installed (parameterise vehicle management computer). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Intarder failure Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04533

EEC1 CAN message not received EEC1 = Electronic Engine Controller 1. EEC1 is the name of the message that is sent from the EDC control unit (A435) or the vehicle management computer (A403) and contains information about engine torque. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of vehicle management computer Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04534

CCVS CAN message not received CCVS = Cruise Control/Vehicle Speed. The signal is sent from the vehicle management computer (A403) Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of vehicle management computer Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04535

Not all control lever operations/CCVS message cycle too fast CCVS = Cruise Control/Vehicle Speed. The signal is sent from the vehicle management computer (A403). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Fault in vehicle management computer Fault rectication: Check parameterisation of vehicle management computer (A403) and/or reparameterise.

04536

TCO1 CAN message not received TCO1 is the name of the message and TCO stands for tachograph. The message contains speed information and a malfunction warning ag. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of tachograph/central on-board computer 2 Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04537

EBC2 CAN message not received EBC2 = Wheel speed information. The number 2 denes the content of the message and contains information about wheel speed. The signal is sent from the EBS control unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of EBS Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04538

EEC2 CAN message not received EEC2 = Electronic Engine Controller 2. EEC2 is the name of the message sent by the EDC control unit (A435) or vehicle management computer (A403). The message contains signals from the accelerator, kick down or the load in force at the current speed. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of vehicle management computer Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

134

T 39

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04539

ETC1 CAN message not received ETC1 = Electronic Transmission Control 1. This message is sent from the vehicle management computer. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of gearbox control unit Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04540

ETC2 CAN message not received ETC2 = Electronic Transmission Control 2. The number 2 denes the content of the message and contains information about gear display and shift arrows. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of gearbox control unit Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04541

TC1 CAN message not received TC1 = Transmission Control 1. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of vehicle management computer/gearbox control unit Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04542

VDC1 CAN message not received VDC1 = Vehicle Dynamic Stability Control 1. The signal is sent from ESP. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of ESP/EBS and/or incorrect parameterisation Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04543

AUX1_ZBR CAN message not received AUX1_ZBR is a message from the central computer 2 (A302) (switch statuses, check lamps). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of central on-board computer 2/combined instrument Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04544

Cannot send ACC1/last send message has not been sent yet Fault reaction: Controlled ACC deactivation is performed. Fault cause: Unable to send messages at the driveline CAN data bus. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check the cables and plug connectors of the driveline CAN data bus for short-circuit or line disconnection. Check cables and plug connectors of the ACC, measure resistance at the driveline CAN data bus.

04545

Cannot send DM1/last send message has not been sent yet DM1 = Diagnostic Message 1 and is used to send an active fault message. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Unable to send messages at the driveline CAN data bus. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check the cables and plug connectors of the driveline CAN data bus for short-circuit or line disconnection. Check cables and plug connectors of the ACC, measure resistance at the driveline CAN data bus.

T 39

2nd edition

135

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04546

Synchronisation fault/TCO1 CAN messages not received in cycle TCO1 = Tachograph. This message contains speed information and a malfunction warning ag. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Tachograph failure Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check parameterisation of tachograph (A408) and/or reparameterise. Check the cables and plug connectors of the driveline CAN data bus for short-circuit or line disconnection.

04547

WEIG CAN message not received The CAN message “Vehicle weight” from EBS control unit (A402) is not received. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of EBS. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04548

ALB CAN message not received The CAN message “Axle load” from EBS control unit (A402) is not received. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Failure of EBS Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04549

Unable to send Trans-Conf request/unable to request Trans-Cong CAN message Fault reaction: Unable to activate ACC. Fault cause: Unable to send messages at the driveline CAN data bus. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Check the cables and plug connectors of the driveline CAN data bus for short-circuit or line disconnection. Check cables and plug connectors of the ACC, measure resistance at the driveline CAN data bus.

04550

No conguration messages/Trans,Rx,Rd,Re,Ccvs Cong not received Fault reaction: Unable to activate ACC. Fault cause: No conguration messages Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. If in combination with other messages: check parameterisation of ACC control unit (A479) and reparameterise.

04551

Eng-Conf CAN messages not received The engine conguration message is sent from the EDC control unit (A435). Fault reaction: Controlled ACC deactivation is performed. Fault cause: EDC failure Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system.

04552

Check EBC1 timeout/timeout was only detected by additional monitoring EBC1 = Electronic Brake Controller 1. This message is sent from the EBS control unit (A402) and contains signals related to the brake pedal and/or the ABS and ASR statuses. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Control unit fault. Fault rectication: Check parameterisation of the ACC control unit (A479)/replace ACC control unit

136

T 39

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04553

Check brake/excessive braking time only detected in additional monitoring The signal is sent from the ACC control unit (A479). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Control unit fault Fault rectication: Check parameterisation of the ACC control unit (A479)/replace ACC control unit

04554

Check TCO1 tachograph timeout/timeout was only detected by additional monitoring TCO1 = Tachograph. This message contains speed information and a malfunction warning ag. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Control unit fault Fault rectication: Check parameterisation of the ACC control unit (A479)/replace ACC control unit

04555

Check delay/excessively long delay was only detected in additional monitoring The signal is sent from the ACC control unit (A479). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Control unit fault Fault rectication: Check parameterisation of the ACC control unit (A479)/replace ACC control unit

04556

Sensor CAN fault/if Bus-Off is reached In the event of Bus-Off, the control unit is not taking part in CAN communication. The signal is sent from the sensor CAN data bus. Fault reaction: Controlled ACC deactivation is performed. Fault cause: ACC distance sensor, sensor CAN data bus fault Fault rectication: Check the cables and plug connectors of the sensor CAN data bus for short-circuit or line disconnection. Test step: Measure resistance: ACC distance sensor, sensor CAN data bus; ACC control unit – pin X1/10 (+) and pin X1/12 (-): approx. 60 Ω (control unit connected); approx. 120 Ω (control unit disconnected); at approx. 0 Ω short-circuit from CAN-High to CAN-Low.

04557

SSTA not received Message from the ACC distance sensor (B574) is not received. Fault reaction: Controlled ACC deactivation is performed. Fault cause: The ACC distance sensor is not supplied with 12 V. Sensor CAN data bus not connected correctly. Fault rectication: Check the wiring, fuse of 12 V power supply (F216) or voltage converter (T119). Check the cables and plug connectors of the sensor CAN data bus for short-circuit or line disconnection. Test steps: Measure voltage: Power supply for ACC distance sensor; ACC distance sensor – pin 1 (+) and pin 2 (-): ~= 12 V Measure resistance: Sensor CAN data bus; ACC control unit – pin X1/10 (+) and pin X1/12 (-): approx. 60 Ω (control unit connected); approx. 120 Ω (control unit disconnected); at approx. 0 Ω short-circuit from CAN-High to CAN-Low.

T 39

2nd edition

137

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04558

STGT not received Message from the ACC distance sensor (B574) is not received. Fault reaction: Controlled ACC deactivation is performed. Fault cause: The ACC distance sensor is not supplied with 12 V. Sensor CAN data bus not connected correctly. Fault rectication: Check the wiring, fuse of 12 V power supply (F216) or voltage converter (T119). Check the cables and plug connectors of the sensor CAN data bus for short-circuit or line disconnection. Test steps: Measure voltage: Power supply for ACC distance sensor; ACC distance sensor – pin 1 (+) and pin 2 (-): ~= 12 V Measure resistance: Sensor CAN data bus; ACC control unit – pin X1/10 (+) and pin X1/12 (-): approx. 60 Ω (control unit connected); approx. 120 Ω (control unit disconnected); at approx. 0 Ω short-circuit from CAN-High to CAN-Low.

04559

STGT2 not received Message from the ACC distance sensor (B574) is not received. Fault reaction: Controlled ACC deactivation is performed. Fault cause: The ACC distance sensor is not supplied with 12 V. Sensor CAN data bus not connected correctly. Fault rectication: Check the wiring, fuse of 12 V power supply (F216) or voltage converter (T119). Check the cables and plug connectors of the sensor CAN data bus for short-circuit or line disconnection. Test steps: Measure voltage: Power supply for ACC distance sensor; ACC distance sensor – pin 1 (+) and pin 2 (-): ~= 12 V Measure resistance: Sensor CAN data bus; ACC control unit – pin X1/10 (+) and pin X1/12 (-): approx. 60 Ω (control unit connected); approx. 120 Ω (control unit disconnected); at approx. 0 Ω short-circuit from CAN-High to CAN-Low.

04560

Radar fault/internal radar fault The signal is sent from the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: General fault of ACC distance sensor Fault rectication: Check the wiring, fuse of 12 V power supply (F216) or voltage converter (T119). Check the cables and plug connectors of the sensor CAN data bus for short-circuit or line disconnection. Test steps: Measure voltage: Power supply for ACC distance sensor; ACC distance sensor – pin 1 (+) and pin 2 (-): ~= 12 V Measure resistance: Sensor CAN data bus; ACC control unit – pin X1/10 (+) and pin X1/12 (-): approx. 60 Ω (control unit connected); approx. 120 Ω (control unit disconnected); at approx. 0 Ω short-circuit from CAN-High to CAN-Low. Replace the ACC distance sensor and recalibrate it if the cause of the fault is not clear.

04561

Radar fault/incorrect or irreparably damaged radar software (ERROR_SOFTWARE1) The signal is sent from the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: ACC distance sensor not responding and/or faulty. Fault rectication: Replace and recalibrate ACC distance sensor.

138

T 39

2nd edition

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04562

Radar fault/incorrect or irreparably damaged radar software (ERROR_SOFTWARE2) The signal is sent from the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: ACC distance sensor not responding and/or faulty. Fault rectication: Replace and recalibrate ACC distance sensor.

04563

Radar fault/supply voltage too high The signal is sent from the voltage converter (T119). Fault reaction: Controlled ACC deactivation is performed. Fault cause: 12 V power supply unavailable Fault rectication: Check 12 V power supply of the voltage converter – see also SI 191302a Test step: Measure voltage: Power supply for ACC distance sensor – pin 1 (+) and pin 2 (-): ~= 12 V

04564

Radar fault/supply voltage too low The signal is sent from the voltage converter (T119). Fault reaction: Controlled ACC deactivation is performed. Fault cause: 12 V power supply unavailable Fault rectication: Check 12 V power supply of the voltage converter – see also SI 191302 Test step: Measure voltage: Power supply for ACC distance sensor – pin 1 (+) and pin 2 (-): ~= 12 V

04565

Radar fault/TRM too hot This refers to the high-frequency unit 1st temperature sensor. The signal is sent from the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: High-frequency unit too hot Fault rectication: Terminal 15 off, wait, terminal 15 on and wait to see if the fault re-occurs, otherwise replace the ACC distance sensor.

04566

Radar fault/TRM too cold This refers to the high-frequency unit 1st temperature sensor. The signal is sent from the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: High-frequency unit too cold Fault rectication: Terminal 15 off, wait, terminal 15 on and wait to see if the fault re-occurs, otherwise replace the ACC distance sensor.

04567

Radar fault/PCM too hot This refers to the high-frequency unit 2nd temperature sensor. The signal is sent from the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: PCM too hot Fault rectication: Terminal 15 off, wait, terminal 15 on and wait to see if the fault re-occurs, otherwise replace the ACC distance sensor.

04568

Radar fault/sensor CAN bus fault Fault reaction: Controlled ACC deactivation is performed. Fault cause: Sensor CAN data bus function unavailable Fault rectication: Check the cables and plug connectors of the sensor CAN data bus and the ACC control unit (A479) for short-circuit or line disconnection. Test step: Measure resistance: Sensor CAN data bus; ACC control unit – pin X1/10 (+) and pin X1/12 (-): approx. 60 Ω (control unit connected); approx. 120 Ω (control unit disconnected); at approx. 0 Ω short-circuit from CAN-High to CAN-Low. T 39

2nd edition

139

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04569

Radar fault/sensor CAN message fault Fault reaction: Controlled ACC deactivation is performed. Fault cause: Sensor CAN data bus function unavailable Fault rectication: Check the cables and plug connectors of the sensor CAN data bus and the ACC control unit (A479) for short-circuit or line disconnection. Test step: Measure resistance: Sensor CAN data bus; ACC control unit – pin X1/10 (+) and pin X1/12 (-): approx. 60 Ω (control unit connected); approx. 120 Ω (control unit disconnected); at approx. 0 Ω short-circuit from CAN-High to CAN-Low.

04570

Radar fault/no parameter settings The signal is sent from the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: ACC control unit (A479) parameterised incorrectly Fault rectication: Reparameterise ACC control unit and recalibrate ACC distance sensor.

04571

Radar fault/pairing fault The signal is sent from the ACC control unit (A479) and the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: ACC control unit and ACC distance sensor do not have identical ID. Fault rectication: Reparameterise ACC control unit and recalibrate ACC distance sensor.

04572

Radar fault/HF switched off HF = high-frequency unit. The signal is sent from the ACC control unit (A479) and the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: High-frequency unit is switched off Fault rectication: Reparameterise ACC control unit and recalibrate ACC distance sensor.

04573

Radar fault/sensor alignment fault The signal is sent from the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: ACC distance sensor has detected that it is incorrectly aligned. Fault rectication: Recalibrate ACC distance sensor.

04574

Radar fault/background noise fault The signal is sent from the ACC distance sensor (B574). Fault reaction: Controlled ACC deactivation is performed. Fault cause: Excessive background noise Fault rectication: No known remedy. Terminal 15 off. Replace the ACC distance sensor if the fault re-occurs. Reparameterise ACC control unit and recalibrate ACC distance sensor

04575

Radar fault/antenna blocked A radar sensor (also called an antenna) works as the ACC distance sensor in high-frequency operation and a transmission frequency of 76-77 GHz. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Radar antenna is blocked Fault rectication: Remove panel and clean. Remove dirt and/or ice, etc. from the ACC distance sensor.

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DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04576

ESP gyro fault Gyro = yaw rate sensor (B476). This fault occurs only in vehicles with ESP. The signal is sent from the EBS control unit (A402). Fault reaction: Controlled ACC deactivation is performed. Fault cause: ESP no longer supplies this message to the driveline CAN data bus for the ACC control unit (A479). Incorrect parameterisation. Fault rectication: Read out diagnostic memory of the “Overall vehicle” with MAN-cats® II and rectify the faults in the corresponding system. Load the conversion data le. Check EBS control unit for functionality and parameterisation, check parameterisation of the ACC control unit (A479) and/or reparameterise

04577

Cannot send YRSContr./last gyro request not sent Gyro = yaw rate sensor (B476). This fault occurs only in vehicles without ESP. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Unable to request yaw rate sensor. Sensor CAN data bus is interrupted. Fault rectication: Check the cables and plug connectors of the sensor CAN data bus and the ACC control unit (A479) for short-circuit or line disconnection. If only in combination with SPN diagnostic code 04578; check cable harness for yaw rate sensor. Test step: Measure resistance: Sensor CAN data bus; ACC control unit – pin X1/10 (+) and pin X1/12 (-): approx. 60 Ω (control unit connected); approx. 120 Ω (control unit disconnected); at approx. 0 Ω short-circuit from CAN-High to CAN-Low.

04578

Cannot receive YRSData/gyro message not received Gyro = yaw rate sensor (B476). This fault occurs only in vehicles without ESP. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Unable to request yaw rate sensor. Sensor CAN data bus is interrupted. Fault rectication: Check the cables and plug connectors of the sensor CAN data bus and the ACC control unit (A479) for short-circuit or line disconnection. If only in combination with SPN diagnostic code 04577; check cable harness for yaw rate sensor. Test step: Measure resistance: Sensor CAN data bus; ACC control unit – pin X1/10 (+) and pin X1/12 (-): approx. 60 Ω (control unit connected); approx. 120 Ω (control unit disconnected); at approx. 0 Ω short-circuit from CAN-High to CAN-Low.

04579

YRS fault/internal gyro fault or wrong ID Gyro = yaw rate sensor (B476). This fault occurs only in vehicles without ESP. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Yaw rate sensor supplies faults or sends incorrect ID code. Fault rectication: Check functionality of yaw rate sensor, check parameterisation of ACC control unit (A479) or reparameterise; if fault cause is not clear, replace yaw rate sensor

04580

Cannot send SVEH The signal is sent from the sensor CAN data bus. Fault reaction: Controlled ACC deactivation is performed. Fault cause: Sensor CAN data bus is disrupted. Fault rectication: Check the cables and plug connectors of the sensor CAN data bus and the ACC control unit (A479) for short-circuit or line disconnection. If single fault, check cabling; if in combination with SPN diagnostic codes 04577 and 04578, check yaw rate sensor cable harness; if in combination with SPN diagnostic codes 04577, 04578 and 04557, 04558, 04559, check entire cable harness or plug connector on ACC control unit. Test step: Measure resistance: Sensor CAN data bus; ACC control unit – pin X1/10 (+) and pin X1/12 (-): approx. 60 Ω (control unit connected); approx. 120 Ω (control unit disconnected); at approx. 0 Ω short-circuit from CAN-High to CAN-Low. T 39

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141

DEVICE DESCRIPTION

SPN

SPN-Plain text Description

04581

Yaw rates installation/internal gyro installed incorrectly Gyro = yaw rate sensor. The signal is sent from the yaw rate sensor (B476). Fault reaction: Unable to activate ACC. Fault cause: Yaw rate sensor tted incorrectly Fault rectication: Fit yaw rate sensor correctly: the direction indicated on the adhesive label on the side of the yaw rate sensor must always point along the vehicle, not across the vehicle.

04582

Transverse acceleration installation/internal gyro installed incorrectly Gyro = yaw rate sensor. The signal is sent from the yaw rate sensor (B476). Fault reaction: Unable to activate ACC. Fault cause: Yaw rate sensor tted incorrectly Fault rectication: Fit yaw rate sensor correctly: the direction indicated on the adhesive label on the side of the yaw rate sensor must always point along the vehicle, not across the vehicle.

04583

User stack fault The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace the ACC control unit if the fault is permanent

04584

Unit AT fault The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace the ACC control unit if the fault is permanent

04585

ACC status fault The signal is sent from the ACC control unit (A479). Fault reaction: ACC control unit function cancelled. Fault cause: Control unit fault Fault rectication: Replace the ACC control unit if the fault is permanent

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DEVICE DESCRIPTION Test step list The test step list enables the components and/or functions of the ACC to be checked with the break box, a multi-function measuring device (multimeter) and a FLUKE ScopeMeter 123. Test description In the list of test steps given in this Chapter (example: test step 1), the rst test contact is identied with “pin X2/8” and the second test contact with “pin X1/3”. Use a multi-function measuring device (multimeter) to measure the resistance between these pins. This involves direct measurement of ACC components. The measuring mode to be set on the multi-function measuring device (multimeter) is shown between columns Pin+ and Pin- that specify the test contacts. Example:

Setting “V” = Voltage measurement

Example:

Setting “Ω” = Resistance measurement

Once the test conditions have been met, the value displayed on the multi-function measuring device (multimeter) (actual property) can be compared with the setpoint value (nominal property). The break box is connected between the vehicle management computer and the vehicle. All jumpers must be closed in the break box. The jumper at which the value is being measured must be open. Test step list for ACC without multi-function steering wheel (A943) SN: ................................................................

Test performed by: ..........................................................

Customer: ..........................................................

First registration: .............................................

Vehicle type: .................................................

Vehicle identier: ............................................

Engine type: .......................................................

Engine number: ..............................................

.......................................................................

Control unit no.: ...........................................

Mileage: .................................................

Date: .........................................................

Read out the diagnostic memory of the ACC control unit (A479) using MAN-cats® II. Use the test step list to locate the entered active faults. – Use brief overviews and/or circuit diagrams for the specic vehicle in question when troubleshooting. – Voltage measurements are taken with the ignition switched on, the engine running and the vehicle stationary. – Resistance measurements are taken with the ignition switched off. – Voltage and resistance values are measured between the positive connection (pin+) and negative connection (pin-) on the multi-function measuring device (multimeter). – Never measure at the plug contacts themselves without using suitable test probes! Danger of bending open the contacts! Resistance measurement – Ignition “OFF” – Disconnect and connect the plug connector from the control unit on which the measurement is being made. Stalk switch for cruise control/gearbox Comment: The values are measured directly on the vehicle management computer.

T 39

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143

DEVICE DESCRIPTION

Vehicle management computer pin designation

Measuring device

Setpoint value [Ω]

Pin+

Pin-

X2/8

X1/3

60607

31000

X1/7

X1/3

Cable number

60608

31000

Road speed limiter check lamp Stalk switch for cruise control/gearbox (A429)

X2/17

X1/3

Cable number

60609

31000

Gearbox cruise control and retarder data line Stalk switch for cruise control/gearbox (A429) Cable number Gearbox cruise control and retarder clock line Stalk switch for cruise control/gearbox (A429)

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Measured value [Ω]

Vehicle management Vehicle computer

FFR

Vehicle

~= 1.5 MΩ Plug connector connected

~= 1.6 MΩ Plug connector disconnected

.........

.........

~= 1.2 MΩ Plug connector connected

~= 1.7 MΩ Plug connector disconnected

.........

.........

~= 8.4 kΩ Plug connector connected

~= 1.67 kΩ Plug connector disconnected

.........

.........

2nd edition

DEVICE DESCRIPTION Cruise control/road speed limiter switch Comment: in the active state, the switch is closed. The values are measured directly on the vehicle management computer. Vehicle management computer pin designation

Measuring device Pin+

Pin-

Cruise control/road speed limiter request, cruise control/road speed limiter switch (S284) Closed: road speed limiter Open: cruise control

X2/16

X1/3

Cable number

60521

31000

Setpoint value [Ω]

~= 4.6 kΩ

Measured value [Ω]

..................

Continuous brake switch Comment: in the active state, the switch is closed. The values are measured directly on the vehicle management computer. Vehicle management computer pin designation

Measuring device Pin+

Pin-

Request, intelligent brake function (coupling) TGA: Continuous brake switch (S479)

X1/16

X1/3

Cable number

60610

31000

Setpoint value [Ω]

~= 4.6 kΩ

Measured value [Ω]

..................

CAN data bus Comment: No 120 Ω terminating resistor is integrated in the ACC control unit. ACC control unit pin designation Resistance between driveline CAN-High and driveline CAN-Low – ACC control unit disconnected Wire colour Resistance between driveline CAN-High and driveline CAN-Low – ACC control unit connected Wire colour Resistance between sensor CAN-High and sensor CAN-Low – ACC control unit disconnected Wire colour

Measuring device Pin+

Pin-

X1/14

X1/15

blue /red

Setpoint value [Ω]

Measured value [Ω]

approx. 60 Ω No terminating resistor!

..................

approx. 60 Ω

..................

approx. 120 Ω

..................

blue /white

X1/14

X1/15

blue /red

blue /white

X1/10

X1/12

red /yellow

yellow /red

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DEVICE DESCRIPTION

ACC control unit pin designation Resistance between sensor CAN-High and sensor CAN-Low – ACC control unit connected Wire colour

Measuring device Pin+

Pin-

X1/10

X1/12

Setpoint value [Ω]

approx. 60 Ω red /yellow

Measured value [Ω]

..................

yellow /red

Voltage measurement – Ignition “ON” – The measurement is made directly on the control unit, sensor, button, etc. Voltage is measured with the engine running and the vehicle stationary. The operating voltage is approximately 28 V; the operating voltage range is 16 – 32 V ACC control unit power supply Comment: Pin X1/3 is connected to terminal 31 – battery ground. ACC control unit pin designation ACC control unit power supply – Terminal 15 ACC fuse, terminal 15 (F413) Cable number ACC control unit power supply – Terminal 30 ACC fuse, terminal 30 (F414) Cable number

Measuring device Pin+

Pin-

X1/2

X1/3

60029

31000

X1/1

X1/3

60030

31000

Setpoint value [V]

Measured value [V]

16 - 32 V (UBat)

..................

16 - 32 V (UBat)

..................

Yaw rate sensor power supply Yaw rate sensor pin designation Yaw rate sensor power supply Voltage converter (T119) Cable number

Measuring device Pin+

Pin-

1

2

165

166

Setpoint value [V]

~= 12 V

Measured value [V]

..................

ACC distance sensor power supply ACC distance sensor pin designation ACC distance sensor power supply Voltage converter (T119) Cable number

146

Measuring device Pin+

Pin-

1

2

165

166

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2nd edition

Setpoint value [V]

~= 12 V

Measured value [V]

..................

DEVICE DESCRIPTION Power supply for ACC range button ACC range button pin designation Power supply for ACC distance button (S550) – terminal 15 Cable number Power supply for location lighting of ACC distance button (S550) Cable number Power supply for ACC range button (S550) – Reduce distance Cable number Power supply for ACC range button (S550) – Increase distance Cable number

Measuring device Pin+

Pin-

2

5

60029

31000

8

7

58000

31000

3 (4)

5

60630

31000

4 (3)

5

60630

31000

Setpoint value [V]

16 - 32 V (UBat)

Measured value [V]

..................

16 - 32 V (UBat) Light switch (S111) switched on

..................

16 - 32 V (UBat) Pressing the button down establishes a connection to terminal 15

..................

0 V, pressing the button up establishes a connection to ground

..................

Cruise control/road speed limiter switch Comment: in active state (road speed limiter), the switch is closed. The values are measured directly on the vehicle management computer. Vehicle management computer pin designation

Measuring device Pin+

Pin-

Cruise control/road speed limiter request Cruise control/road speed limiter switch (S284) – Road speed limiter function

X2/16

X1/3

Cable number

60521

31000

Cruise control/road speed limiter request Cruise control/road speed limiter switch (S284) – Cruise control function

X2/16

X1/3

Cable number

60521

31000

Setpoint value [V]

Measured value [V]

UTL15 switch closed (switch pressed down; connection to terminal 15): road speed limiter

..................

0 V switch open (switch pressed up; connection to terminal 15 interrupted): FGR

..................

Comment: The value is measured directly on the cruise control/road speed limiter switch.

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DEVICE DESCRIPTION Cruise control/road speed limiter switch pin designation Search light power supply Cruise control/road speed limiter switch (S284) Cable number

Measuring device Pin+

Pin-

8

7

58000

31000

Setpoint value [V]

16 - 32 V (UBat)

Measured value [V]

..................

Continuous brake switch Comment: The switch is closed in active status (continuous brake activated). The values are measured directly on the vehicle management computer. Vehicle management computer pin designation

Measuring device Pin+

Pin-

Request, intelligent brake function (coupling) Continuous brake switch (S479) – Continuous brake activated

X1/16

X1/3

Cable number

60610

31000

Request, intelligent brake function (coupling) Continuous brake switch (S479) – Continuous brake deactivated

X1/16

X1/3

Cable number

60610

31000

Setpoint value [V]

Measured value [V]

UTL15 switch closed (switch pressed down; connection to terminal 15)

..................

0 V switch open (switch pressed up; connection to terminal 15 interrupted):

..................

Comment: The value is measured directly on the continuous brake switch. Continuous brake switch pin designation Search light power supply Continuous brake switch (S479) Cable number

Measuring device Pin+

Pin-

8

7

58000

31000

Setpoint value [V]

16 - 32 V (UBat)

Measured value [V]

..................

Stalk switch for cruise control/gearbox Comment: The values are measured directly on the vehicle management computer. The break box is used for measuring the voltage values of the cruise control/gearbox stalk switch. – The break box is connected between the vehicle management computer and the vehicle cable harness. – All jumpers must be closed in the break box. The “gearbox cruise control and retarder data line” and “gearbox cruise control and retarder clock line” measuring steps are also performed with the jumper open.

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DEVICE DESCRIPTION

Vehicle management computer pin designation Gearbox cruise control and retarder data line Stalk switch for cruise control /gearbox (A429) Cable number Gearbox cruise control and retarder clock line Stalk switch for cruise control /gearbox (A429) Cable number

Setpoint value [V] Measuring device

Jumper opened

Pin+

Pin-

X2/8

X1/3

60607

31000

X1/7

X1/3

60608

31000

Vehicle management computer pin designation

Measured value [V]

Measuring device Pin+

Pin-

Road speed limiter check lamp Stalk switch for cruise control/gearbox (A429)

X2/17

X1/3

Cable number

60609

31000

T 39

Jumper Jumper opened Jumper closed closed Vehicle FFR Vehicle

FFR

~= 23.5 V

~= 14.2 V

~= 14.2 V

.......

.......

.......

~= 13.5 V

~= 22.4 V

~= 12.3 V

.......

.......

.......

Setpoint value [V]

Measured value [V]

ON

OFF

ON

OFF

~= 27 V

0V

.........

.........

2nd edition

149

DEVICE DESCRIPTION Driveline CAN data bus Measuring device

ACC control unit pin designation

Pin+

Pin-

Voltage between driveline CAN-High and ground

X1/14

X1/3

Cable colour, cable number

blue/red

31000

Voltage between driveline CAN-Low and ground

X1/15

X1/3

Cable colour, cable number

blue /white

31000

Setpoint value [V]

Measured value [V]

~= 1.8 - 3.2 V Square-wave signal*

..................

~= 1.8 - 3.2 V Square-wave signal*

..................

* Test with a Fluke ScopeMeter 123

The diagram above shows signal characteristics for the driveline CAN data bus high signal (channel A) and the driveline CAN data bus low signal (channel B). Sensor CAN data bus ACC control unit pin designation

Measuring device Pin+

Pin-

Voltage between sensor CAN-High and ground

X1/10

X1/3

Cable colour, cable number

red /yellow

31000

Voltage between sensor CAN-Low and ground

X1/12

X1/3

Cable colour, cable number

yellow /red

31000

* Test with a Fluke ScopeMeter 123

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Setpoint value [V]

Measured value [V]

~= 1.8 - 3.2 V Square-wave signal*

..................

~= 1.8 - 3.2 V Square-wave signal*

..................

DEVICE DESCRIPTION

The diagram above shows signal characteristics for the sensor CAN data bus high signal (channel A) and the sensor CAN data bus low signal (channel B). Diagnostic communication line ACC control unit pin designation

Measuring device Pin+

Pin-

Diagnostic communication line diagnostic socket (X200) Condition: No data trafc on communication line

X1/18

X1/3

Cable number

64205

31000

Diagnostic communication line diagnostic socket (X200) With data trafc on communication line

X1/18

X1/3

Cable number

64205

31000

Setpoint value [V]

Measured value [V]

16 - 32 V (UBat -2 V) (MAN-cats® II not connected)

..................

0 - 32 V (UBat -2 V) (MAN-cats® II connected)

..................

Delete diagnostic memory with MAN-cats® II Read out diagnostic memory and archive the faults. Please delete the diagnostic memory with MAN-cats® II after rectifying all faults. There must not be any faults in the memory when the ignition is switched back on. Otherwise, search for the fault and remedy the problem.

T 39

2nd edition

151

DEVICE DESCRIPTION Test step list for ACC with multi-function steering wheel (A943) SN: ................................................................

Test performed by: ..........................................................

Customer: ..........................................................

First registration: .............................................

Vehicle type: .................................................

Vehicle identier: ............................................

Engine type: .......................................................

Engine number:..............................................

.......................................................................

Control unit no.: ...........................................

Mileage: .................................................

Date: .........................................................

Read out the diagnostic memory of the ACC control unit (A479) using MAN-cats® II. Use the test step list to locate the entered active faults. – Use brief overviews and/or circuit diagrams for the specic vehicle in question when troubleshooting. – Voltage measurements are taken with the ignition switched on, the engine running and the vehicle stationary. – Resistance measurements are taken with the ignition switched off. – Voltage and resistance values are measured between the positive connection (pin+) and negative connection (pin-) on the multi-function measuring device (multimeter). – Never measure at the plug contacts themselves without using suitable test probes! Danger of bending open the contacts! Resistance measurement – Ignition “OFF” – Disconnect and connect the plug connector from the control unit on which the measurement is being made. Button, continuous brake Comment: in the active state, the switch in the button is closed. The values are measured directly on the vehicle management computer. Vehicle management computer pin designation

Measuring device Pin+

Pin-

Request, intelligent brake function (coupling) Continuous brake button (S1133)

X1/16

X1/3

Cable number

60610

31000

152

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2nd edition

Setpoint value [Ω]

~= 4.6 kΩ

Measured value [Ω]

..................

DEVICE DESCRIPTION CAN data bus Comment: No 120 Ω terminating resistor is integrated in the ACC control unit. ACC control unit pin designation Resistance between driveline CAN-High and driveline CAN-Low – ACC control unit disconnected Wire colour Resistance between driveline CAN-High and driveline CAN-Low – ACC control unit connected Wire colour Resistance between sensor CAN-High and sensor CAN-Low – ACC control unit disconnected Wire colour Resistance between sensor CAN-High and sensor CAN-Low – ACC control unit connected Wire colour

Measuring device Pin+

Pin-

X1/14

X1/15

blue /red

Setpoint value [Ω]

Measured value [Ω]

approx. 60 Ω No terminating resistor!

..................

approx. 60 Ω

..................

approx. 120 Ω

..................

approx. 60 Ω

..................

blue /white

X1/14

X1/15

blue /red

blue /white

X1/10

X1/12

red /yellow

yellow /red

X1/10

X1/12

red /yellow

yellow /red

Voltage measurement – Ignition “ON” – The measurement is made directly on the control unit, sensor, button, etc. Voltage is measured with the engine running and the vehicle stationary. The operating voltage is approximately 28 V; the operating voltage range is 16 – 32 V ACC control unit power supply Comment: Pin X1/3 is connected to terminal 31 – battery ground. ACC control unit pin designation ACC control unit power supply – Terminal 15 Cable number ACC control unit power supply – Terminal 30 ACC fuse, terminal 30 (F414) Cable number

Measuring device Pin+

Pin-

X1/2

X1/3

16000

31000

X1/1

X1/3

60030

31000

T 39

2nd edition

Setpoint value [V]

Measured value [V]

16 - 32 V (UBat)

..................

16 - 32 V (UBat)

..................

153

DEVICE DESCRIPTION Yaw rate sensor power supply Yaw rate sensor pin designation Yaw rate sensor power supply Voltage converter (T119) Cable number

Measuring device Pin+

Pin-

1

2

165

166

Setpoint value [V]

~= 12 V

Measured value [V]

..................

ACC distance sensor power supply ACC distance sensor pin designation ACC distance sensor power supply Voltage converter (T119) Cable number

Measuring device Pin+

Pin-

1

2

165

166

Setpoint value [V]

~= 12 V

Measured value [V]

..................

Power supply for ACC range button ACC range button pin designation Power supply for switch or location lighting of ACC distance button (S550) Cable number Power supply for ACC range button (S550) – Reduce distance Cable number Power supply for ACC range button (S550) – Increase distance Cable number Power supply for ACC distance button (S550) – terminal 15 Cable number

154

Measuring device Pin+

Pin-

8

7

16000

31000

3 (4)

2

60630

31000

4 (3)

2

60630

31000

5

2

16000

31000

T 39

2nd edition

Setpoint value [V]

Measured value [V]

16 - 32 V (UBat) Rotary light switch with rear fog lamp (S1112) switched on

..................

16 - 32 V (UBat) Pressing the button down establishes a connection to terminal 15

..................

0 V, pressing the button up establishes a connection to ground

..................

16 - 32 V (UBat)

..................

DEVICE DESCRIPTION Button, continuous brake Comment: The switch is closed in active status (continuous brake activated). The values are measured directly on the vehicle management computer. Vehicle management computer pin designation

Measuring device Pin+

Request, intelligent brake function (coupling) Continuous brake button (S1133) – Continuous brake activated

X1/16

Cable number

60610

Request, intelligent brake function (coupling) Continuous brake button (S1133) – Continuous brake deactivated

X1/16

Cable number

60610

Setpoint value [V]

Pin-

X1/3

31000

X1/3

31000

Measured value [V]

UTL15 switch closed in button; when ignition is turned “ON”, continuous brake is activated automatically; no check lamp will be lit in the button (connection to terminal 15)

..................

0 V switch open in the button; continuous brake is switched off, one check lamp will be lit in the button (button pressed up, connection to terminal 15 interrupted)

..................

Comment: The value is measured directly on the continuous brake button. Continuous brake button, pin designation

Measuring device Pin+

Pin-

8

7

60028

31000

Power supply, switch or location lighting Continuous brake button (S1133) Cable number

Setpoint value [V]

16 - 32 V (UBat)

Measured value [V]

..................

Driveline CAN data bus Measuring device

ACC control unit pin designation

Pin+

Pin-

Voltage between driveline CAN-High and ground

X1/14

X1/3

Cable colour, cable number

blue/red

31000

Voltage between driveline CAN-Low and ground

X1/15

X1/3

Cable colour, cable number

blue /white

31000

Setpoint value [V]

Measured value [V]

~= 1.8 - 3.2 V Square-wave signal*

..................

~= 1.8 - 3.2 V Square-wave signal*

..................

* Test with a Fluke ScopeMeter 123

T 39

2nd edition

155

DEVICE DESCRIPTION

The diagram above shows signal characteristics for the driveline CAN data bus high signal (channel A) and the driveline CAN data bus low signal (channel B). Sensor CAN data bus ACC control unit pin designation

Measuring device Pin+

Pin-

Voltage between sensor CAN-High and ground

X1/10

X1/3

Cable colour, cable number

red /yellow

31000

Voltage between sensor CAN-Low and ground

X1/12

X1/3

Cable colour, cable number

yellow /red

31000

Setpoint value [V]

Measured value [V]

~= 1.8 - 3.2 V Square-wave signal*

..................

~= 1.8 - 3.2 V Square-wave signal*

..................

* Test with a Fluke ScopeMeter 123

The diagram above shows signal characteristics for the sensor CAN data bus high signal (channel A) and the sensor CAN data bus low signal (channel B). 156

T 39

2nd edition

DEVICE DESCRIPTION Diagnostic communication line ACC control unit pin designation

Measuring device Pin+

Pin-

Diagnostic communication line diagnostic socket (X200) Condition: No data trafc on communication line

X1/18

X1/3

Cable number

64205

31000

Diagnostic communication line diagnostic socket (X200) With data trafc on communication line

X1/18

X1/3

Cable number

64205

31000

Setpoint value [V]

Measured value [V]

16 - 32 V (UBat -2 V) (MAN-cats® II not connected)

..................

0 - 32 V (UBat -2 V) (MAN-cats® II connected)

..................

Delete diagnostic memory with MAN-cats® II Read out diagnostic memory and archive the faults. Please delete the diagnostic memory with MAN-cats® II after rectifying all faults. There must not be any faults in the memory when the ignition is switched back on. Otherwise, search for the fault and remedy the problem.

T 39

2nd edition

157

ADDITIONAL CIRCUIT DIAGRAMS

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEWS

T 39

2nd edition

159

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITH ESP – OLD VERSION (TGA) As at: 09/2004 Legend A100 A302 A403 A429 A479 B574 F125 F413 F414 F583 R258 S550 T119 X200 X1642 X1644 X2541 X2542 X2544 X3287 ——– B1 E6 E7 F F1 F2 F4

Central electrical system Central computer 2 Vehicle management computer Stalk switch for cruise control/gearbox ACC control unit ACC distance sensor Fuse, location lighting ACC fuse (terminal 15) ACC fuse (terminal 30) Vehicle management computer fuse (terminal 15) switches/sensors Terminating resistor, ACC sensor CAN Button, ACC, distance Modular voltage converter Pl. con. 37-pin diagnosis (MAN-cats) Ground point, cab, behind combined instrument Ground point, cab, next to central electrical system 21-pin potential distributor for line 31000 21-pin potential distributor for line 58000 21-pin potential distributor, communication line Cab member, left ACC ———————————————————————— Installation location, engine Installation location, central electrical system area Installation location, control units, plug-in modules Installation location, instrument panel Installation location, middle section Installation location, steering column/steering wheel Installation location, front wall, inside left

T 39

2nd edition

160

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITH ESP – OLD VERSION (TGA)

T 39

2nd edition

161

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITHOUT ESP – OLD VERSION (TGA) As at: 09/2004 Legend A100 A302 A403 A429 A479 B574 B476 F125 F413 F414 F583 S550 T119 X200 X1642 X1644 X2204 X2541 X2542 X2544 X3287 ——– C1 E6 E7 F F1 F2 F4 F5 R1

Central electrical system Central computer 2 Vehicle management computer Stalk switch for cruise control/gearbox ACC control unit ACC distance sensor ESP/ACC yaw rate sensor Fuse, location lighting ACC fuse (terminal 15) ACC fuse (terminal 30) Vehicle management computer fuse (terminal 15) switches/sensors Button, ACC, distance Modular voltage converter Pl. con. 37-pin diagnosis (MAN-cats) Ground point, cab, behind combined instrument Ground point, cab, next to central electrical system Pl. con. Cab yaw rate sensor 21-pin potential distributor for line 31000 21-pin potential distributor for line 58000 21-pin potential distributor, communication line Cab member, left ACC ———————————————————————— Installation location, bumper Installation location, central electrical system area Installation location, control units, plug-in modules Installation location, instrument panel Installation location, middle section Installation location, steering column/steering wheel Installation location, front wall, inside left Installation location, front wall, inside right Installation location, frame front section

T 39

2nd edition

162

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITHOUT ESP – OLD VERSION (TGA)

T 39

2nd edition

163

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITH ESP – OLD VERSION (TGS/TGX) As at: 02/2008 Legend A100 A302 A403 A407 A479 A943 B574 F414 R258 S550 T119 X1644 X2541 X2544 X3287 X4397 X4645 ——– B1 E6 E7 F F1 F2 F4 J2

Central electrical system Central computer 2 Vehicle management computer Combined instrument ACC control unit Multi-function steering wheel ACC distance sensor ACC fuse (terminal 30) Terminating resistor, ACC sensor CAN Button, ACC, distance Modular voltage converter Ground point, cab, next to central electrical system 21-pin potential distributor for line 31000 21-pin potential distributor, communication line Cab member, left ACC Pl. con. Multi-function steering wheel 21-pin potential distributor for line 16000 ———————————————————————— Installation location, engine Installation location, central electrical system area Installation location, control units, plug-in modules Installation location, instrument panel Installation location, middle section Installation location, steering column/steering wheel Installation location, front wall, inside left Installation location, A-pillar, co-driver's side

T 39

2nd edition

164

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITH ESP – OLD VERSION (TGS/TGX)

T 39

2nd edition

165

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITHOUT ESP – OLD VERSION (TGS/TGX) As at: 02/2008 Legend A100 A302 A403 A407 A479 A943 B476 B574 F414 S550 T119 X1644 X2204 X2541 X2544 X3287 X4397 X4645 ——– C1 E6 E7 F F1 F2 F4 F5 J2 R1

Central electrical system Central computer 2 Vehicle management computer Combined instrument ACC control unit Multi-function steering wheel ESP/ACC yaw rate sensor ACC distance sensor ACC fuse (terminal 30) Button, ACC, distance Modular voltage converter Ground point, cab, next to central electrical system Pl. con. Cab yaw rate sensor 21-pin potential distributor for line 31000 21-pin potential distributor, communication line Cab member, left ACC Pl. con. Multi-function steering wheel 21-pin potential distributor for line 16000 ———————————————————————— Installation location, bumper Installation location, central electrical system area Installation location, control units, plug-in modules Installation location, instrument panel Installation location, middle section Installation location, steering column/steering wheel Installation location, front wall, inside left Installation location, front wall, inside right Installation location, A-pillar, co-driver's side Installation location, frame front section

T 39

2nd edition

166

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITHOUT ESP – OLD VERSION (TGS/TGX)

T 39

2nd edition

167

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITH OR WITHOUT ESP – NEW VERSION (TGS/TGX) As at: 11/2008 Legend A100 A302 A403 A407 A479 A943 A1124 B574 F413 F414 R258 S550 X1644 X2541 X2544 X3287 X4397 X4645 ——– B1 E6 E7 F F1 F2 F4

Central electrical system Central computer 2 Vehicle management computer Combined instrument ACC control unit Multi-function steering wheel Power Train Manager ACC distance sensor ACC fuse (terminal 15) ACC fuse (terminal 30) Terminating resistor, ACC sensor CAN Button, ACC, distance Ground point, cab, next to central electrical system 21-pin potential distributor for line 31000 21-pin potential distributor, communication line Cab member, left ACC Pl. con. Multi-function steering wheel 21-pin potential distributor for line 16000 ———————————————————————— Installation location, engine Installation location, central electrical system area Installation location, control units, plug-in modules Installation location, instrument panel Installation location, middle section Installation location, steering column/steering wheel Installation location, front wall, inside left

T 39

2nd edition

168

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITH OR WITHOUT ESP – NEW VERSION (TGS/TGX)

T 39

2nd edition

169

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITH ESP – OLD VERSION (P11/P12/P14/P15/P16) As at: 08/2005 Legend A100 A302 A403 A429 A479 B574 F413 F414 F628 R258 R262 S550 T119 X2544 X3013 X3313 X3720 ——– C C1 D E7 F F1

Central electrical system Central computer 2 Vehicle management computer Stalk switch for cruise control/gearbox ACC control unit ACC distance sensor ACC fuse (terminal 15) ACC fuse (terminal 30) Fuse for terminal 15 Terminating resistor, ACC sensor CAN ACC heating sensor panel (not currently tted) Button, ACC, distance Modular voltage converter 21-pin potential distributor, communication line Pl. con. Instrument panel 1 Pl. con. ACC 12 V adaptation Pl. con. ACC main control panel ———————————————————————— Installation location, front Installation location, bumper Installation location, main control panel Installation location, control units, plug-in modules Installation location, instrument panel Installation location, interface, instrument panel

T 39

2nd edition

170

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITH ESP – OLD VERSION (P11/P12/P14/P15/P16)

T 39

2nd edition

171

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITH ESP – NEW VERSION (P11/P12/P14/P15/P16) As at: 12/2009 Legend A100 A302 A403 A407 A479 A942 A943 B574 F413 F414 F628 R258 S550 X1968 X2544 X3013 X3720 ——– C D E7 F F1

Central electrical system Central computer 2 Vehicle management computer Combined instrument ACC control unit Stalk switch for retarder/gearbox Multi-function steering wheel ACC distance sensor ACC fuse (terminal 15) ACC fuse (terminal 30) Fuse for terminal 15 Terminating resistor, ACC sensor CAN Button, ACC, distance Pl. con. Cruise control switch 21-pin potential distributor, communication line Pl. con. Instrument panel 1 Pl. con. ACC main control panel ———————————————————————— Installation location, front Installation location, main control panel Installation location, control units, plug-in modules Installation location, instrument panel Installation location, interface, instrument panel

T 39

2nd edition

172

ADDITIONAL CIRCUIT DIAGRAMS BRIEF OVERVIEW, ACC WITH ESP – NEW VERSION (P11/P12/P14/P15/P16)

T 39

2nd edition

173