A40 Common Rail In-Line Engines [PDF]

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Note Installation position of XI586 for semitrailer E8!

Central electrical system Central computer 2 Battery 2 Socket N 24V Plug connection, frame I Plug connection, connection, trailer socket 1

Legend Trailer socket, 24V 7-pin N A

Trailer socket, 24V 7-pin sheet 1 of 1 Status: 07.1999

WIRING DIAGRAM NO. 81.99192.2496

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ADDITIONAL WIRING DIAGRAM5

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Installation position of XI586 and XI587 for semitrailer E8!

Central electrical system Central computer 2 Battery 2 Socket N 24V Trailer socket (reversing light and rear fog lamp) Plug connection, frame I Plug connection, connection, trailer socket 1 Plug connection, connection, trailer socket 2

Legend Trailer socket, 24V 7-pin N A Trailer socket, 24V 4-pin N B

Trailer socket, 24V 7-pin + 4-pin sheet 1 of 1 Status: 07.1999

WlRlNG DIAGRAM NO. 81.99192.2497

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ADDITIONAL WIRING DIAGRAMS

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Central electrical system DC transformer, 24 1 12V Central computer 2 Battery 2 Socket N 24V Trailer socket (reversing light and rear fog lamp) Plug connection, frame I Plug connection, connection, trailer socket 1 Plug connection, connection, trailer socket 2

Legend Trailer socket, 24V 7-pin N A B Trailer socket, 24V 4-pin

Trailer socket, 24V 7-pin + C p i n and 12V 13-pin sheet 1 of 2 Status: 03.1999

WIRING DIAGRAM NO. 81.99192.2448

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ADDITIONAL WIRING DIAGRAMS

A 100 A236 A302 X740

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Central electrical system DC transformer, 24 / 12V Central computer 2 Trailer socket 12V

Legend A Trailer socket, 12V 13-pin

Trailer socket, 24V 7-pin + 4-pin and 12V 13-pin sheet 2 of 2 Status: 07.1999

WIRING DIAGRAM NO. 81.99192.2448

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E,"llation position of X I 586 and XI587 for semitrailer E8!

Central electrical system Central computer 2 Battery 2 Socket S 24V Socket N 24V Plug connection, frame I Plug connection, connection, trailer socket 1 Plug connection, connection, trailer socket 2

Legend Trailer socket, 24V 7-pin N A Trailer socket, 24V 7-pin S B

Trailer socket, 24V 7-pin + 7-pin sheet 1 of 1 Status: 07.1999

WIRING DIAGRAM NO. 81.99192.2498

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ADDITIONAL WIRING DIAGRAMS

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A100 A236 A302 G l 01 X329 X330 X I 540 XI586 X I 587

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Central electrical system DC transformer, 24 1 12V Central computer 2 Battery 2 Socket S 24V Socket N 24V Plug connection, frame I Plug connection, connection, trailer socket 1 Plug connection, connection, trailer socket 2

Legend A Trailer socket, 24V 7-pin N Trailer socket, 24V 7-pin S B

Trailer socket, 24V 7-pin + 7-pin and 12V 13-pin sheet 1 of 2 Status: 03.1999

WIRING DIAGRAM NO. 81.99192.2449

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ADDITIONAL WIRING DIAGRAMS --

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Central electrical system DC transformer, 24 1 12V Central computer 2 Trailer socket 12V

Legend A Trailer socket, 12V 13-pin

Trailer socket, 24V 7-pin + 7-pin and 12V 13-pin sheet 2 of 2 Status: 07.1999

WRING DIAGRAM NO. 81.99192.2449

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ADDITIONAL WIRING DIAGRAMS ---

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Central electrical system DC transformer, 24 1 12V Central computer 2 Battery 2 Socket N 24V Trailer socket 12V Plug connection, frame I Plug connection, connection, trailer socket 1 Plug connection, connection, trailer socket 2

Legend Trailer socket, 24V 7-pin N A B Trailer socket, 12V 13-pin

Trailer socket, 24V 7-pin and 12V 13-pin sheet 1 of 1 Status: 03.1999

WIRING DIAGRAM NO. 81.99192.2447

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ADDITIONAL WIRING DIAGRAMS

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Central electrical system Central computer 2 Floodlight, left Fuse, floodlights Switch, floodlights Plug connection, floodlight, left Plug connection, floodlight in roof, left Potential distributor, 21-pin, line 31000 Potential distributor, 21-pin, line 58000

Legend A Floodlights

Floodlights, cab roof (left) sheet 1 of 1 Status: 08.2001

WRING DIAGRAM NO. 81.99192.1 534

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WIRING DIAGRAM NO. 81.99192.1356

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Central electrical system Central computer 2 Floodlight, right Floodlight, left Fuse, floodlights Switch, floodlights Plug connection, floodlight, left Plug connection, floodlight in roof, left Plug connection, floodlight in roof, right Plug connection, floodlights Potential distributor, 21-pin, line 31 000 Potential distributor, 21-pin, line 58000

Floodlights

Status: 04.2001

) Floodlights, cab roof (left, right) sheet 1 of 1

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Legend E l 77 Lighting, ashtray, left X2541 Potential distributor, 21-pin, line 31000 X2542 Potential distributor, 21-pin, line 58000

Ashtray lighting, left sheet 1 of 1 Status: 12.2002

WIRING DIAGRAM NO. 85.99192.2059

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ADDITIONAL WIRING DIAGRAMS

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El78 X2541 X2542

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Lighting, ashtray, right Potential distributor, 21-pin, line 31000 Potential distributor, 21-pin, line 58000

Ashtray lighting, right sheet 1 of 1 Status: 11.2002

WIRING DIAGRAM NO. 85.99192.2020

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Central electrical system Central computer 2 Instrumentation Check lamp, ASR info.

For basic equipment, see wiring diagram for EBS

A1 00 A302 A407 HI40

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Legend A ASR check lamp

ASR check lamp sheet 1 of 1 Status: 04.2001

WIRING DIAGRAM NO. 81.99192.1358

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A1 00 A302 A402 S256 X2541 X2542

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Central electrical system Central computer 2 Control unit, EBS Button, ASR or ASRIESP slip threshold increase Potential distributor, 21-pin, line 31000 Potential distributor, 21-pin, line 58000

Legend A ASR slip thresholds

ASR slip threshold button sheet 1 of 1 Status: 11.2002

WIRING DIAGRAM NO. 85.99192.2021

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ADDITIONAL WIRING DIAGRAMS ---

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Auxiliary heater

Central electrical system Central computer 2 Instrumentation Fuse, alternator (terminal 15) Check lamp, emergency off fault Relay, EMERGENCY OFF, alternator Switch, EMERGENCY OFF, cab, external Switch, isolator switch, battery Switch, EMERGENCY OFF, cab 8-diode cluster, battery isolator switch Plug connection, auxiliary heater, battery master switch, electrical Plug connection, enginelEDClgearbox II Earthing point, cab, next to central electrical system Crimped connector, line 59104 Plug connection, EMERGENCY OFF-alternator, terminal 15 Plug connection, EMERGENCY OFF, switch, external Plug connection, auxiliary water heater - battery isolator switch Potential distributor, 21-pin, line 58000

Legend A Battery EMERGENCY OFF

Battery EMERGENCY OFF sheet 1 of 2 Status: 12.2003

WlRlNG DIAGRAM NO. 81.99192.1685

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ADDITIONAL WIRING DIAGRAMS

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Central electrical system Central computer 2 Control unit, battery isolator switch, battery EMERGENCY OFF I F128 Fuse, permanent load Fuse, central on-board computer, continuous positive ) F243 J F522 Fuse line 30000 I F523 Fuse line 30000 ) G I 00 Battery 1 )GI01 Battery2 1 MI00 Starter J Q105 Isolator switch, battery + J XI00 Ground connection, engine I XI557 Plug connection, frame, left ! ~ 2 1 7 7 Plug connection, EMERGENCY OFF, switch, external )X3437 Plug connection, frame, left II

) A100 ) A302 ) A317

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Battery EMERGENCY OFF sheet 2 of 2 Status: 10.2002

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WIRING DIAGRAM NO. 81.99192.1685

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Error list Address Error code 20 031 16 20 031 17 20 031 18 20 031 19 03120 20 20 03121 20 03122 20 03123 20 03124 03125 20 20 03126

Meaning CAN data bus: EDC message EDC4, byte 0 CAN data bus: EDC message EDC4, byte 1 CAN data bus: EDC message EDC4, byte 2 CAN data bus: EDC message EDC4, byte 3 CAN data bus: EDC message EDC4, bytes 4 and 5 CAN data bus: EDC message EDC4, byte 6 CAN data bus: EDC message EDC4, byte 7 CAN data bus: EDC message EDC5, byte 0 CAN data bus: EDC message EDC5, byte 1 CAN data bus: EDC message EDC5, bytes 2 and 3 CAN data bus: EDC message EDC5, byte 4

Error list Address 38 38

Error Meaning code 03230 Setpoint level control 03231 Leakage

List of addresses Address

Control unit

EBS lntarder Door module, driver's seat Door module, co-driver's seat EDC AS Tronic Vehicle management computer Central on-board computer ZBR II ECAS Instrumentation

DIAGNOSIS

System structure, K-lines

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

X200

ACC AIRBAG CD DPFIGDK EBS ECAM ECASIEFR EDC FFR FSS

Adaptive cruise control Control unit, airbag Instrument panel Diesel partic. filterlcontr. diesel cat. Electronic brake system Electr. controlled air management Electr. controlled air suspension Electronic diesel control Vehicle management computer Driver seat control unit

GET HZG KLlMA KSM RET TM TM 1 ZBR II X200

Gearbox control unit Heating control Air-conditioning system Customer-specified module RetarderAntarder control Door module, driver side Door module, co-driver side Central on-board computer with Diagnosis socket

Electrical System Key, Code Numbers Line Numbers, Symbols, Diagnosis ...

Publication no.:

MAN Nutzfahrzeuge Aktiengesellschaft Dachauer Str. 667 oder Postfach 50 06 20 80995 M~JNCHEN 80976 M~JNCHEN

Device List 2nd edition T 60

Elektrische Anlage Gerateliste Gerateliste T 60 (2. Ausgabe) - englisch Printed in Germany

Electrical System

Device List T 60 (2nd edition)

Key, Code Numbers Line Numbers, Symbols, Diagnosis ...

ELECTRICAL SYSTEM Table of contents Electrical system.......................................................................................................................... Table of contents .......................................................................................................................... Abbreviations................................................................................................................................

0 0.11 .1 0.13 .1

General information...................................................................................................................... 1 Notes on safety ............................................................................................................................ 1.20 .1 Key to wiring diagrams ................................................................................................................ 2 Code letter A Control units .............................................................................................. 2.01 .1 Code letter B Sensors. pressure switches. pickups ..........................................................2.02 .1 Code letter C Condensers................................................................................................. 2.03 .1 Code letter E Lighting........................................................................................................ 2.05 .1 Code letter F Protective devices (fuses,...) ..................................................................... 2.06 .1 Code letter G Alternator, battery ........................................................................................ 2.07 .1 Code letter H Checking and warning devices.................................................................. 2.08 .1 Code letter K Relays ......................................................................................................... 2.1 1 .1 Code letter M Motors ......................................................................................................... 2.1 3 .1 Code letter N Amplifiers, controllers .................................................................................. 2.1 4 .1 Code letter P Gauges and instruments ............................................................................. 2.1 6 .1 Code letter Q Master switches ......................................................................................... 2.1 7 .1 Code letter R Resistors .................................................................................................... 2.1 8 .1 Code letter S Switches ................................................................................................... 2.1 9 .1 Code letter T Transformers, voltage dividers .................................................................. 2.20 .1 Code letter V Diodes ......................................................................................................... 2.22 .1 Code letter W Antennae, connection lines ......................................................................... 2.23 .1 Code letter X Terminals, plug connections, plug distributors ............................................ 2.24 .1 Code letter Y Solenoid valves ........................................................................................... 2.25 .1 Code letter Z Filters, diplexers .......................................................................................... 2.26 .1 Wiring diagram line numbers ................................................................................................ 3 04 Ignition system ................................................................................................................... 3.04 .1 05 Fuel system. supply .heating................................................................................................ 3.05 .1 13 Fire extinguisher system. fire suppression system ................................................................ 3.1 3 .1 14 Safety devices. emergency mode. emergency shut.off. intrinsically safe circuits ................. 3.14 .1 15 Voltage supply (terminal 15) .................................................................................................. 3.15 . 1 16 Monitoring devices. tachograph ...................................................................................... 3.16 .1 17 Bulbs. flame start system ...................................................................................................... 3.17 . 1 20 Washers and wipers .............................................................................................................. 3.20 .1 23 Air-conditioning system ......................................................................................................... 3.23 .1 24 Heating. auxiliary heaters. battery heating ............................................................................ 3.24 .1 25 Ventilation.............................................................................................................................. 3.25 .1 30 Voltage supply, positive ......................................................................................................... 3.30 .1 31 Voltage supply. negative ................................................................................................. 3.31 .1 32 Electric motors ....................................................................................................................... 3.32 .1 37 Ticket cancelling machine ................................................................................................. 3.37 .1 40 Gearbox ............................................................................................................................ 3.40 .1 43 Retarderlengine brake...................................................................................................... 3.43 .1 49 Turn indicators and hazard warning lights............................................................................. 3.49 .1 50 Starter control ........................................................................................................................ 3.50 .1 55 Masked lighting ..................................................................................................................... 3.55 .1 56 Headlight low beam. headlight high beam. fog lamps. rear fog lamps .................................. 3.56 .1 57 Park light ............................................................................................................................... 3.57 .1 58 Parking lights. sidelights. tail lights ........................................................................................ 3.58 .1 59 Alternator. power generation ................................................................................................. 3.59 .1 60 Engine. electronic engine management (EMS). electronic accelerator................................. 3.60 .1 61 Fan drive. coolant .................................................................................................................. 3.61 .1 62 Radio set ............................................................................................................................... 3.62 .1

ELECTRICAL SYSTEM ABBREVIATIONS FM FMI FMR FOC FSCH FSG FSH FTW FUNK FZA

Vehicle management Failure Mode ldentification Vehicle engine control Front Omnibus Chassis Windscreen heating Artificial roadway equipment Window heating Driver's cab partition Communications radio set Destination display

GDK GEN GET GGVS GND GP GS GV

Closed-loop diesel exhaust catalytic converter Generator Transmission Ordinance regulating the movement of dangerous goods by road Ground (or earth) Planetary gear group -transmission (post-shift group) Transmission control Pre-shift group - transmission (splitter group)

HA HBA HGB HGS HLUE HOC HSS HST HU Hz HZA HZG

Rear axle Secondary braking system Maximum speed limit Hydraulic gearshift Hydrostatic fan Heck Omnibus Chassis Highside switch Main switch panel Main examination Hertz (alternationslperiod per second) Halt sign facility Auxiliary engine speed pickup

IBEL IBIS IC ID IMR INA IR IRM IS0 IWZ

Interior lamps lntegrated vehicle information system lntegrated Circuit Identification lntegrated mechanical relay (start-up control) Information display (e.g. control lamp) Individual control (ABS) Modified individual control (ABS) International Standardization Organization Incremental angle-time measuring system

KBZ KFH KlTAS KLI KNEEL KSM KSW KWP

Combi-brake cylinder Fuel filter heating Kienzle Intelligent Tachograph-Sensor Air-conditioning unit Kneeling Customer-specific control module Customer option Key Word Protocol (protocol for diagnosis with MAN-cats)

LBH LCD LDA LDF LDS LED

Air vessel Liquid Crystal Display Charge pressure-sensitivefull-load stop Charge pressure sensor Air suspension damping system Light Emitting Diode

KEY TO WIRING DIAGRAMS Code letter H

H95 H l 00 HlOl H102 H103 H104 H105 H106 H107 HI08 HI09 HllO H111 HI12 H113 H114 H115 HI16 HI17 HI18 HI19 HI20 HI21 HI22 HI23 HI24 HI25 HI26 HI27 H128 H129 H130 HI31 H132 H133 H134 H I 35

Checking and warning devices

Check lamp, coolant level Check lamp, stop, "central warning light" Check lamp, oil pressure Electric horn Electric horn, Fiamm, low frequency Steering pressure check Air horn Electric horn, Fiamm, high frequency Steering oil check Check, gearbox oil temperature Check lamp, for S33.1 only Check lamp, turn indicators, trailer Check lamp, gearbox oil temperature Buzzer, operating state Electric horn, reverse gear Check lamp, ABS fault Check lamp, ASR control Check lamp, ASR control, diagnosis Check lamp, EDC Check lamp, EMS, diagnosislwarning device Check lamp, EMS, warning device Check lamp, 2nd alternator Charge check lamp Check lamp, flame start system Signal horn Check, level deviation Check, door open Buzzer, frost warning, air-conditioning system Gong, PA system ABS, tractorltrailer Check lamp, reservoir pressure Check lamp, oil pressure Check lamp, coolant temperature Central warning light, STOP Brake lamp, right Brake lamp, left Additional brake lamp, right top Additional brake lamp, left top Check lamp, central lubrication system Check lamp, parking brake Check lamp, turn indicators, tractor Check lamp, turn indicators, trailer Turn indicator, front right Turn indicator, front left Turn indicator, rear right Turn indicator, rear left Turn indicator, side right Turn indicator, side left Turn indicator at rear, right top Turn indicator at rear, left top Check lamp, undervoltage protection Check lamp, headlight high beam Check lamp, roof flaps Check lamp, air-conditioning system Warning buzzer, emergency valve Check lamp, call steward Check lamp, toilet Check lamp, toilet Check lamp, toilet waste tank fulllfresh water empty

KEY TO WIRING DIAGRAMS Check lamp, ENGAGED Check lamp, central locking Check lamp, luggage compartment flap Charge check lamp, alternator 2 Check lamp, air suspension, warning Check lamp, ABS, tractor Check lamp, central lubrication system Check lamp, ASR info. Check lamp, EDC Ielectronic accelerator Check lamp, EMS (fault) Horn 2 Check lamp, ECAS (fault) Check lamp, ECASIEFR (fault) Check lamp, ECAS (warning) Check lamp, ECASIEFR (warning) Check lamp, retarder Warning buzzer, reverse gear for driver Check lamp, pressure drop, gearbox Warning buzzer, driver Check lamp, tipper Check lamp, cab lock Check lamp, pressure drop, gearbox Check lamp, ABS, trailer Buzzer, reverse gear Check lamp, ABS info., trailer Check lamp, coolant level Additional turn indicator, front left Additional turn indicator, front right Warning buzzer, intercom system Check lamp, power steering Air horn Check lamp, hydraulic system Check lamp, crane Check lamp, converter-clutch unit Check lamp, gearbox, oil temperature Warning buzzer Check lamp, power take-off Check lamp, differential lock, rear axle Check lamp, differential lock, front axle Check lamp, differential lock, interaxle Check lamp, off-road range Check lamp, neutral position Signal horn (two-tone) Check lamp, emergency operation, outside, door 1+2 Masked brake lamp, left Masked brake lamp, right Check lamp, steering oil level indicator Check lamp, priority vehicle light, right Siren for anti-theft warning system Check lamp, emergency release device Check lamp, seat belt Check lamp, tyre pressure control system Check lamp, gearbox, status monitor Check lamp, body (multi) Check lamp, body (multi) Warning buzzer, reverse gear, vehicle, outside Check lamp, monitor, rear axle load Check lamp, ENGAGED Check lamp, combined mode Check lamp, trailing axle, steering, fault Check lamp, emergency valve warning, front

KEY TO WIRING DIAGRAMS Check lamp, frequent-stop brake Warning buzzer, differential lock, transverse, front axle Check lamp, support system Warning buzzer, door monitor, body Check lamp, door monitor, body Check lamp, 2nd priority vehicle light High-volume horn, low High-volume horn, high Check lamp, cable winch Check lamp, splitter group Warning buzzer, differential lock, transverse, rear axle Check lamp, gritter Panel of check lamps for H I 80 and H I 81 Warning buzzer, engine and brake circuit monitoring Check lamp, coolant temperature, 105 degrees Check lamp, gearbox, oil pressure Check lamp, gearbox, oil temperature Check lamp, gearbox, oil level Check lamp, axle lock-out, front axles Check lamp, axle lock-out, rear axles Panel of check lamps for H204 and H205 Check lamp, levelling Panel of check lamps for H207 Warning buzzer, frequent-stop brake not applied Check lamp, 5-axle steering, supply OK Check lamp, 5-axle steering, rear axle, straight-ahead steering Check lamp, system, central computer Check lamp, alarm (red) Check lamp, early warning (yellow) Warning buzzer, instrument panel 1 Warning buzzer, instrument panel 2 Warning buzzer, instrument panel 3 Check lamp, customer's special request 1 Check lamp, customer's special request 2 Check lamp, customer's special request 3 Check lamp, customer's special request 4 Check lamp, customer's special request 5 Check lamp, customer's special request 6 Check lamp, servomotor fault Warning buzzer, door closing warning, door 2 Warning buzzer, door closing warning, door 3 Warning buzzer, door closing warning, door 4 Check lamp, pram Check lamp, door 3 Check lamp, door 4 Check lamp, door open Check lamp, door closed Check lamp, release Check lamp, stop symbol system Ceiling sign, bus stopping (front section) Ceiling sign, bus stopping (tractor) Warning buzzer, bell, departure Check lamp, gas filter Check lamp, engine fault Check lamp, lift Warning light, lift, outside, front Warning light, lift, outside, rear Warning light, lift, inside Warning buzzer, lift Check lamp, trailing axlelleading axle, steering, warning (yellow) Check lamp, trailing axlelleading axle, steering, fault (red)

KEY TO WIRING DIAGRAMS Diode, economy circuit Diode, turn indicators, right Diode, hazard warning lights Diode, turn indicators, left Diode, turn indicators, school bus readiness Diode group, retarder operation (Verona circuit) Diode group, retarder operation (Verona circuit) Diode, voltage supply, body, multi Diode group V100, V154 Diode, interior heating Diode group V255, V365, V366, V367 Diode group V255, V258, V259, V340 Diode, interior heating Diode, interior heating Diode, "ON" at ignition Diode, self-holding Diode group, IBIS on Diode, control suppression, ECAS Diode, control suppression, ECAS Diode group, control suppression, ECAS Diode, retarder, reduction Diode, retarder, reduction Diode group V266, V267 Diode group V270, V271 Diode, door 1 open Diode, door 2 open Diode group V406, V407, V408 Diode group V409, V410, V411, V412 Diode group V275, V276, V290, V291 Diode group, cab lock, anti-theft warning system Diode group, cab lock, anti-theft warning system Diode, brake lamp, retarder Diode, retarder, self-holding Diode group V277, V278 Diode group, axle lock-out, hydropneumatic suspension Diode group, axle lock-out, hydropneumatic suspension Diode, engine stop Diode, taillift Diode, headlight high beam Diode, headlight low beam Diode, frequent-stop brake Diode, hillholder Diode group V284, V285, V286, V287 Diode D+ (CNG) Diode, mute, anti-theft warning system Diode, rear distributor, anti-theft warning system Diode, emergency valve warning, door 3 Diode, emergency valve warning, door 4 Diode group V295, V296 Diode, oil top-up, "WAKE-UP" Diode, hazard warning lights, "WAKE-UP" Diode group V388, V389 Diode, check, hydraulic system Diode, fan motor, auxiliary heater Diode, fan motor, air-conditioning system Diode group V298, V299 Diode, power steering Diode group, brakelparking brake Diode group, stop request Diode, disabled button Diode group V404, V405

KEY TO WIRING DIAGRAMS Diode group - PLM Diode group- 2 x Diode, power take-off IIPLM Diode, ISG 1 Diode, power take-off IIIPLM Diode group, axle lock-out, hydropneumatic suspension Diode group, axle lock-out, hydropneumatic suspension Diode group, axle lock-out, hydropneumatic suspension Diode group V313, V314 Diode, shut-off, roof duct blower, if door feed Diode, "levelling" Diode group, hillholder Diode group V316, V317 Diode, circulating pump Diode, thermostat switch Diode group V224, V225 Double diode V320, V321 Diode, tipper lowering Diode group, engine stop (CNG) Diode group, engine stop (CNG) Diode, roof ventilator Diode, roof ventilator Diode group V323, V324 Diode group for "NUMMEK axle" Diode for "NUMMEK axle" Diode for GDK Diode group, "WAKE-UP" Diode, intermediate speed governor Diode group V154, V173 Diode for instrument panel, line 15002 Diode for instrument panel, line 58013 Diode group V335, V336 Diode, turn indicators, left Diode, turn indicators, right Diode group V338, V291 Diode, entry lighting Diode group V143, V144, V340, V341 Diode, heating Diode, ventilation Diode group V248, V249 Diode group V335, V336, V349, V350 Diode, stop signal request, door 3 Diode, opening, pram, door 3 Diode, keep open, door 3 Diode group, pram, door 3 Diode, stop signal request, door 4 Diode, turn indicators, left Diode, turn indicators, right Diode group V352, V353 Diode, axle load monitor Diode, check, axle monitor Diode, disconnectable rear loading crane Diode, turn indicator, left (middle) Diode, turn indicator, right (middle) Diode, turn indicator, left (rear, top) Diode, turn indicator, right (rear, top) Diode group V355, V356, V357, V358 Diode group, headlight high beamlheadlight low beam, driving school Diode, flame start system Diode, gearbox splitter and range-change groups Diode group V121, V186, V427

KEY TO WIRING DIAGRAMS Diode, MANEX trailing axle Diode group V121, V340, V427, ... Diode, compressor Diode group V175, ... Diode, economy circuit Diode group V431 Diode, stop request Diode, CNG control Diode, CNG control Diode group V429, V441, V518 Diode, relay, ignition system Diode, relay, ignition system Diode group, CNG Diode, shut-off cylinder, CNG Diode, exhaust flap, CNG Diode, CNG control Diode, driver light Diode group, stop request Diode, stop request, wheelchair Diode, stop request, pram Diode group, voltage supply Diode on at ignition Diode, door 2 open Diode, enable Diode group, voltage supply Diode on at ignition Diode, door 3 open Diode group, voltage supply Diode on at ignition Diode, door 4 open Diode group V456, V457, V486, V487 Diode, retarder Diode, retarder Diode, roof flaps open Diode, roof flaps open Diode group, auxiliary heater Diode group, triple Diode, oil level Diode, dirty oil Diode, auxiliary compressor Diode, battery box heater Diode, battery box heater Diode group for V465, V466 Diode group V469, V470, V471, V ... Diode, intermediate speed governor Diode, intermediate speed governor Diode, intermediate speed governor Diode group V422, V473 Diode, compressor relief valve Diode group, masked light Diode group, masked light Diode group, slanted seat valve Diode, slanted seat valve (front section) Diode, slanted seat valve (tractor) Diode, roof flap 3, rear, open Diode, roof flap 3, rear, open Diode, roof flap 3, front, open Diode group, roof flap 3 Diode, heater control, continuous positive Diode, heater control, ignition Diode group, heater control

KEY TO WIRING DIAGRAMS Plug connection, charging socket Plug connection, seat heating, right Plug connection, seat heating, left Plug connection, storage locker lighting, right Plug connection, sliding roof Plug connection, storage locker lighting, top Plug connection, storage locker lighting, left Plug connection, storage locker lighting, right Plug connection, refrigerator Plug connection, cargo space lighting Plug connection, bunk lighting, bottom Plug connection, water pump, auxiliary heater Plug connection, temperature sensor, retarder (water, oil) Jumper, WAKE-UP, auxiliary heater Isolating point, ramp Plug connection, refuelling ECU, equipment board Plug connection, refuelling ECU, equipment board Plug connection, interior lighting Plug connection, switch, interior lighting Plug connection, main and wide-angle mirror, right Plug connection, main and wide-angle mirror, left Plug connection, kerb mirror, right Plug connection, kerb mirror, left Plug connection, interface, trailer socket 1 Plug connection, interface, trailer socket 2 Plug connection, side marker light Plug connection, washer pump Plug connection, line 43005 Plug connection, CAN databus for EDC Plug connection, TS-CAN databus for ECAM Jumper, throttle valve potentiometer, electronic accelerator, VDO Plug connection, hydrostatic fan drive Plug connection, gearbox oil temperature Plug connection, tank sensor Plug connection, kerb mirror heater, additional Plug connection, voltage supply, EASY-SHIFT Plug connection, working spotlights Plug connection, rack, central wiring Plug connection, rack, central wiring Plug connection, axle steering, EMPL Connector, tank data, preparation Plug connection, switch in gearshift knob Jumper, IBIS continuous positive Jumper, ticket cancelling machine, continuous positive Plug connection, line 31017 Plug connection, automatic gearbox-engine brake, EDC Plug connection, automatic gearbox-engine brake, EDC Vehicle-isolating point 1 Vehicle-isolating point 2 Vehicle-isolating point, driver's area Vehicle-isolating point, road speed governor Isolating point, driver's area Isolating point, road speed governor Plug connection, trailer control module Jumper for relay, air-conditioning system, front end Plug connection, roof ventilator, right Plug connection, roof ventilator, left Plug connection, roof ventilator, right Plug connection, roof ventilator, left Distributor for line 15002 Distributor for line 31000

1

KEY TO WIRING DIAGRAMS Plug connection, line 40558 Plug connection, line 40597 Distributor, line 70003 Connector, tank data Connector, tank data loop, fuel Connector, tank data loop, gearbox oil Connector, tank data loop, coolant Connector, tank data loop, fresh oil Connector, tank data loops Crimped connector, line 60028 Crimped connector, line 70003 Crimped connector, line 16500 Plug connection, R gear signal Interface, components Plug connection, retarder Plug connection, equipment board (air-conditioning systemlheating), tractor Plug connection, cab-ACC Plug connection, masked tail lightlbrake lamp, right Plug connection, engine stop, 3-pole Plug connection, reversing buzzer Plug connection, relay, winter service Plug connection, relay, winter service Plug connection, relay, winter service Plug connection, relay, winter service Plug connection, relay, winter service, driver side Plug connection, relay, winter service, co-driver side Plug connection, relay, brake wear indicator without Autocheck Plug connection, relay, brake wear indicator without Autocheck Plug connection, relay, ABSIASR-2M Stage 112 Jumper on central electrical system, item 40 Socket, 12V, Pakistan Plug connection, 3-pole, C 0 2 extinguisher system Plug connection, temperature gauge, additional Plug connection, gearbox, gear interlock Plug connection, 3-pole, button, C 0 2 extinguisher system Plug connection, interior lighting, line 30075 Plug connection, tunnel, ABSIASR-2M Stage Y2 Plug connection, tunnel, ABSIASRPM Stage Y2 Plug connection, 3-pole, trigger, C 0 2 extinguisher system Plug connection, 1-pole, D+ relay, NCIKC alternator Plug connection, 3-pole, gear lock-out device Plug connection, 8-pole, ABS-valve, rear axle Plug connection, ADM, cab-chassis Plug connection, ADM, cab-chassis Plug connection, ADM, distributor, line 40017 Plug connection, ADM, diagnosis Plug connection, traffic light transmitter Ultrasonic weld, driveline Plug connection, switch, sliding roof Plug connection, cab-co-driver door Plug connection, cab-driver door Plug connection, cab-co-driver door Plug connection, cab-driver door Crimped connector, line 58304 Crimped connector, line 58305 Plug connection, video monitor Plug connection, loudspeakers, shielded Plug connection, auxiliary battery Line distributor 31009 Line distributor 37300 Line distributor 37301

.

.

KEY TO WIRING DIAGRAMS Plug connection, cab-frame, check, crane Plug connection, distributor box, ground, crane Potential distributor, 21-pole, line 31000 Potential distributor, 21-pole, line 58000 Potential distributor, 21-pole, line 30006 Potential distributor, 21-pole, K-line Socket, cable winch control Plug connection, pilot switch and solenoid valve, power take-off 1 Crimped connector, line 31004 Plug connection, equipment board, front Plug connection, equipment board, rear Plug connection, instrument panel 1 Plug connection, instrument panel 2 Plug connection, instrument panel 3 Plug connection, rear lights, top left Plug connection, auxiliary brake switch Plug connection, accelerator pedal sensor Plug connection, front end-node Plug connection, rear end-node Plug connection, masked light, "follow-me light" Plug connection, diagnosis, K-line, central computer (ZBRO) Plug connection, cab, tyre pressure control system Plug connection, receptacle, tyre pressure control system Plug connection, tyre pressure control system, line 58314 Plug connection, voltage supply, vehicle management computer Plug connection, voltage supply, EBS Plug connection, voltage supply, ECAS Plug connection, voltage supply, ECAM Plug connection, vehicle management computer - main switchboard Plug connection, EBS - main switchboard Plug connection, ECAS - main switchboard Plug connection, central on-board computer - main switchboard Crimped connector, line 15029 Crimped connector, line 30314 Plug connection, front end-node Plug connection, distributor, line 30000 Plug connection, distributor, line 30009 Chassis earth distributor, luminous bar, right Chassis earth distributor, luminous bar, left Relay socket K250, K609 Plug connection, cablroof (luminous bar) Plug connection, proximity switch Isolating point, ground connection, engine Plug connection, adaptation, fuel pressure controller Plug connection, equipment board, front for ECE36 Plug connection, equipment board, rear for ECE36 Plug connection, taillift Line divider, line 5831 1 Line divider, line 58357 Line divider, line 58366 Line divider, line 58375 Line divider, line 31000 Plug connection, battery box, equipment board, rear Plug connection, equipment board, central locking Crimped connector, line 15029 Plug connection, resistor bank Distributor, line 31000 Plug connection, glove compartment Distributor, line 15029 Distributor, line 30314 Plug connection, control unit, airbag

I

KEY TO WIRING DIAGRAMS

Code letter Y

YlOO YlOl Y102 Y103 Y104 Y105 Y106 Y107 Y108 Y109 YllO Ylll

Solenoid valves

Solenoid valve Solenoid valve, engine brake Solenoid valve, differential lock, interaxle Solenoid valve, differential lock Control valve, spare wheel cover Solenoid valve, overload, trailing axle Solenoid valve, lowering, rear left, trailing axle Solenoid valve, lowering, rear right, trailing axle Solenoid valve, ABS, front right Solenoid valve, ABS, rear right Solenoid valve, lowering, front left Solenoid valve, lowering, front right Solenoid valve, raising Solenoid valve, lowering, rear left Solenoid valve, lowering, rear right Solenoid valve, ABS, front left Solenoid valve, ABS, rear left Oil separator (Haldex) Solenoid valve, ASR Injection pump: Regulator, MS5-Stage 213, M(S)5-Stage 3 Solenoid valve, kneeling, front left Solenoid valve, kneeling, front right Solenoid valve, kneeling, rear left Solenoid valve, kneeling, rear right Solenoid valve, block, air suspension Hand lever valve, retarder Solenoid valve, lntarder Solenoid valve, retarder, level 1 Solenoid valve, accumulator Solenoid valve, retarder, reduction Y5 Solenoid valve, engine speed increase Solenoid valve, retarder Solenoid valve, retarder, level 2 Solenoid valve, retarder Solenoid valve, retarder, level 3 Solenoid valve, accumulator Solenoid valve, flame start system Solenoid valve, white smoke reduction Solenoid valve, engine stop, engine brake Solenoid valve, road speed limiter Solenoid valve, central lubrication pump Solenoid valve, warm water, front left Solenoid valve, warm water, front right Solenoid valve, warm water, rear left Solenoid valve, warm water, rear right Solenoid valve, fresh air flap, roof Solenoid valve, recirculated air flap, roof Pressure control valve, front left Solenoid valve, warm water, roof Pressure control valve, front right Solenoid valve, freshlrecirculated air, front end Pressure control valve, middle left Solenoid valve, engine speed increase Pressure control valve, middle right Magnetic clutch, compressor Pressure control valve, rear left Solenoid valve, toilet flush Solenoid valve, ABS, rear left

.

.

KEY TO WIRING DIAGRAMS Plug connection, cab-frame, check, crane Plug connection, distributor box, ground, crane Potential distributor, 21-pole, line 31000 Potential distributor, 21-pole, line 58000 Potential distributor, 21-pole, line 30006 Potential distributor, 21-pole, K-line Socket, cable winch control Plug connection, pilot switch and solenoid valve, power take-off 1 Crimped connector, line 31004 Plug connection, equipment board, front Plug connection, equipment board, rear Plug connection, instrument panel 1 Plug connection, instrument panel 2 Plug connection, instrument panel 3 Plug connection, rear lights, top left Plug connection, auxiliary brake switch Plug connection, accelerator pedal sensor Plug connection, front end-node Plug connection, rear end-node Plug connection, masked light, "follow-me light" Plug connection, diagnosis, K-line, central computer (ZBRO) Plug connection, cab, tyre pressure control system Plug connection, receptacle, tyre pressure control system Plug connection, tyre pressure control system, line 58314 Plug connection, voltage supply, vehicle management computer Plug connection, voltage supply, EBS Plug connection, voltage supply, ECAS Plug connection, voltage supply, ECAM Plug connection, vehicle management computer - main switchboard Plug connection, EBS - main switchboard Plug connection, ECAS - main switchboard Plug connection, central on-board computer - main switchboard Crimped connector, line 15029 Crimped connector, line 30314 Plug connection, front end-node Plug connection, distributor, line 30000 Plug connection, distributor, line 30009 Chassis earth distributor, luminous bar, right Chassis earth distributor, luminous bar, left Relay socket K250, K609 Plug connection, cablroof (luminous bar) Plug connection, proximity switch Isolating point, ground connection, engine Plug connection, adaptation, fuel pressure controller Plug connection, equipment board, front for ECE36 Plug connection, equipment board, rear for ECE36 Plug connection, taillift Line divider, line 5831 1 Line divider, line 58357 Line divider, line 58366 Line divider, line 58375 Line divider, line 31000 Plug connection, battery box, equipment board, rear Plug connection, equipment board, central locking Crimped connector, line 15029 Plug connection, resistor bank Distributor, line 31000 Plug connection, glove compartment Distributor, line 15029 Distributor, line 30314 Plug connection, control unit, airbag

WIRING DIAGRAM LINE NUMBERS 155 15512 15513 15514 15515 15516 15517

Other lines Fuse - control unit, BUSE Fuse - supply, RACK, terminal 15 Fuse - supply, proximity switch, starter interlock Fuse - supply, TRIVECTOR 18 Supply, TRIVECTOR T8 Supply, card

I

WIRING DIAGRAM LINE NUMBERS 32

Electric motors

320 32001

Supply (from fuses or master switch) Fuse F226 - control unit, gritter

321

Pickups, sensors, check lamps (incl. check lamp in diagnosis button) Consumers Button, sunblind - sunblind, right Button, sunblind - sunblind, left or full-width Button, sunblind - sunblind, right Button, sunblind - sunblind, left or full-width Switch - control unit, gritter Fuse F228 - motor, gritter Sunblind Sunblind Motor, gritter Auxiliary button, sunblind, right, co-driver Auxiliary button, sunblind, right, co-driver Other lines Control unit, fuse F227 - gritter Fuse F227 - relay K310, gritter Control unit, fuse F228 Switch, gritter Pilot switch, flap, front-end "Klimator" heater Pilot switch, flap, ECAS valves Pilot switch, flap, battery compartment Pilot switch, flap, silencer Pilot switch, rear silencerlengine Pilot switch, battery compartment (tractor) Supply for camera Limit switch, stowage compartment, right

~

WIRING DIAGRAM LINE NUMBERS Ticket cancelling machine Supply (from fuses or master switch) Fuse, ticket cancelling machine continuous positive - shut-off relay Shut-off relay - switch-on relay Fuse, IBIS - shut-off relay Shut-off relay - single fuses Supply, IBIS Electro-acoustic supply + Destination displays + Lighting, destination display Supply, PA system Voltage supply, loading recorder lgnition positive, ticket cancelling machine 2 OFF Continuous positive, ticket printer OFF Destination lighting lgnition positive, ticket printer Supply, IBIS Supply, diagnosis computer Supply, on-board computer Spare, destination Spare, destination Voltage supply, destination display Switch, ticket cancelling machine Supply, ignition, tyre pressure monitor, IVTM Supply, ELA Supply, terminal 15 Supply, terminal 15 Supply, terminal 15 Supply, terminal 15 Switching contact, relay, socket Socket, 24V, switched Voltage supply, inside display Voltage supply, inside display Monitor, electronic stability program, supply Pickups sensors, check lamps (incl. check lamp in diagnosis button) Switch, ticket printer Consumers Continuous positive for ticket cancelling machine lgnition positive for ticket cancelling machine Lighting, destination display via economy circuit Lighting, destination display, when parking lights on Paying console Voltage supply, console - changeover relay Voltage supply, control unit - changeover relay Voltage supply, console, filtered Ticket cancelling machine, batt+ switched Ticket cancelling machine, ignition+ switched Destination lighting Destination display Supply, passenger counting system Supply, passenger counting system Computer-controlled central guidance system, radio set Computer-controlled central guidance system 1, supply Computer-controlled central guidance system 2, supply Computer-controlled central guidance system, self-holding Spare line Fuse F592,main switchboard - ceiling Supply, ticket cancelling machine (can be deactivated) Load shedding, destination system

~

WIRING DIAGRAM LINE NUMBERS Electronically controlled air suspension ECASIElectronic shock absorber control ESAC Supply (from fuses or master switch) Voltage supply + (30-ER) SG (ECAS) Voltage supply - (15-ER) SG (ECAS) Switch, loading and unloading (changeover, terminal 15lterminal 30) Switch, trailing axle, raise (voltage supply +15-ER) Relay, supply, terminal 30 (ECASIESAC) Voltage supply, 5V Voltage supply, terminal 15, axle lifting Bellows pressure sensor, tractor Pickups, sensors, check lamps (incl. check lamp in diagnosis button) Check lamp, fault - ECAS Check lamp, warning - ECAS Position sensor, rear axle, left - ECAS Position sensor, rear axle, right - ECAS Position sensor, front axle - ECAS Brake pressure sensor (ESAC) Bellows pressure sensor, rear axle, right Bellows pressure sensor, rear axle, left Accelerator pedal sensor Check lamp, trailing axlelleading axle, raisedlrelieved Check lamp, starting-off aid Activation, bypass, axle lock-out, hydropneumatic suspension Activation, bypass, hydropneumatic suspension Sensor, front axle, right, hydropneumatic suspension Sensor, front axle, left, hydropneumatic suspension Sensor, rear axle, right, hydropneumatic suspension Sensor, rear axle, left, hydropneumatic suspension Sensor 2, front, right, hydropneumatic suspension Sensor 2, front, left, hydropneumatic suspension Sensor 2, rear, right, hydropneumatic suspension Sensor 2, rear, left, hydropneumatic suspension Axle lock-out, rear axle Axle lock-out, all axles Level control, hydropneumatic suspension Sensor, 3rd axle, left Sensor, 3rd axle, right Sensor, 4th axle, left Sensor, 4th axle, right Travel sensor, front axle, right Position sensor, centre axle Axle lock-out, axle 1 Axle lock-out, axle 2 Axle lock-out, axle 3 Axle lock-out, axle 4 Axle lock-out, axle 5 HR-load monitor Door monitor, door 1 Activation, ISG, hydropneumatic suspension Kneeling strip, control unit - door 1 (SZ) Kneeling strip, control unit - door 1 (SZ) Kneeling strip, door 1 - door 2 (SZ) Kneeling strip, door 2 - door 3 (SZ) Kneeling strip, door 3 - door 4 (SZ) Kneeling strip, last door, terminator (SZ) Kneeling strip, last door, terminator (SZ) Check lamp, level 2 Check lamp, brake warning Steering angle potentiometer

WIRING DIAGRAM LINE NUMBERS Control, trailing axle Control, trailing axle Control, trailing axle Control, trailing axle or ECAS Control, trailing axle or leading axle, trailer Axle lock-out, hydropneumatic suspension, solenoid valve, axle 1 Axle lock-out, hydropneumatic suspension, solenoid valve, axle 2 Axle lock-out, hydropneumatic suspension, solenoid valve, axle 3 Axle lock-out, hydropneumatic suspension, solenoid valve, axle 4 Axle lock-out, hydropneumatic suspension, solenoid valve, axle 5 Axle lock-out, hydropneumatic suspension, solenoid valve, unlock Supply, solenoid valves, ECAS Other lines Switch, lower, ECAS (= line, raise) Switch, raise, ECAS (= line, lower) Pressure switch, air reservoir, ECAS Remote control, ECAS (cycle) Remote control, ECAS (data) Switch, level 112, ECAS Pressure switch, ECAS, empty run Pressure switch, ECAS, starting-off aid Button, moving-off aid Switch, trailing axlelleading axle, raiselrelieve Starting-off aid, time relay Level 112, ECAS Sensor, front axle, right, hydropneumatic suspension Sensor, front axle, right, hydropneumatic suspension Sensor, front axle, left, hydropneumatic suspension Sensor, front axle, left, hydropneumatic suspension Sensor, rear axle, right, hydropneumatic suspension Sensor, rear axle, right, hydropneumatic suspension Sensor, rear axle, left, hydropneumatic suspension Sensor, rear axle, left, hydropneumatic suspension Remote control, hydropneumatic suspension Remote control, hydropneumatic suspension Remote control, hydropneumatic suspension Remote control, hydropneumatic suspension Remote control, hydropneumatic suspension Remote control, hydropneumatic suspension Relay, supply, terminal 30 (ECASIESAC) Hydropneurnatic suspension, 5V, voltage supply for sensors, front left and right Hydropneumatic suspension, 5V, voltage supply for sensors, rear left and right Button, kneeling (kneeling lower) Button, kneeling (kneeling raise) ECAS, resistor bank ECAS, resistor bank ECAS, control suppression Frequent-stop brake, kneeling Bus-stop brake, kneeling Vehicle lowered Vehicle lowered Check, vehicle lowered ECAS signal, 15 kmlh Button, lowering Button, raising Button, raising above ride height Switch, manuallautomatic Button, emergency raising Standstill signal Kneeling

CODE NUMBERS Sensors, pressure switches, pickups Temperature sensor Pressure sensor Tank sensor Oil pressure sensor Coolant temperature sensor, switching point 95 "C Pressure switch, NC contact, 5.8 bar Pressure switch, NO contact Pulse generator Pulse generator for tachograph (mechanical) Water level probe Boost pressure sensor, EDC Pedal value sensor Pressure switch, NC contact, 6.5 - 0.4 bar Position sensor for ECAS Temperature sensor Loudspeakers, AL 120 Pressure switch, NO contact, 0.3 - 0.8 bar, Medium Temperature sensor for fan control Loudspeakers Hand-held microphone with helix cable Load sensor Loudspeakerlmicrophone Pressure switch, NO contact, 5.2 bar - 0.4 bar Pressure switch, NO contact, 0.6 bar + 0.3 bar Thermostat switch, TWL Temperature switch, opening at 12 "C, closing at 4 "C Position sensor (G74.2, bayonet 16S), Wabco Pressure sensor Combined highllow-pressure switch Pressure switch, NC contact, 2.0 - 2.6 bar Temperature sensor Loudspeaker 452, oval, Blaupunkt Temperature sensor for fan control Loudspeaker, 50W Loudspeaker, tweeter Position sensor for ECAS Pressure switch, NC contact, 5.8 bar Pressure switch, NO contact, 5.2 bar lnterior thermostat, Thermo 90 Coolant level probe Map board light Pressure transducer Pressure sensor 0 - 10 bar Loudspeaker with moulding lnterior thermostat for auxiliary heater, Thermo Pressure switch, NC contact, 6.5 - 0.4 bar Pressure switch, NC contact, ECAS, empty run Pressure switch, NO contact, 0.3 bar - 0.8 bar Pressure switch, NO contact, 0.7 bar + 0.3 bar Coolant level probe, 3020 VZ18lKZl lnterior thermostat Temperature sensor, interior thermostat Pressure chamber loudspeaker Pedal value sensor Float switch, oil top-up Pressure switch, NO contact, 0.6 bar - 0.9 bar Pressure switch, NO contact, 0.4 bar Hand-held microphone, cordless, Fredrich Temperature sensor, inside, air-conditioning system Temperature sensor, outside, air-conditioning system

CODE NUMBERS Speed sensor Auxiliary speed sensor Boost pressure sensor, EDC Air pressure sensor for emergency release device Light scanner Pressure switch Coolant level probe Loudspeaker with handsfree kit Light scanner Light scanner Rotational speed sensor, ESP Oil level probe Temperature switch, fire detector Coolant level probe Pressure switch, low-pressure switch, G60 Pressure switch, high-pressure switch, G63 Pedal value sensor Sensor, ACC distance sensor Temperature sensor Air pressure switch Rectangular loudspeaker Air pressure switch Air pressure switch Diaphragm pressure switch, NO contact Pedal value sensor Loudspeakers Pressure switch, door panel

Lighting 5-element light, right (for new SR), see H I 02 5-element light, left (for new SR), see H I 03 Light with switch Headlight, left, low beam and parking light Headlight, right, low beam and parking light Headlight, left, high beam Headlight, right, high beam Outline light, front Outline light, rear Fog lamps Light Reading light with gooseneck Light lnterior light Light, halogen (spot) Light lnterior light, sleeping area lnterior light Entrance lighting Licence plate light Side marker light Holder for festoon bulb (socket) Glove compartment light Socket Bulb socket Ceiling light Licence plate light "Follow me" light Masked headlights Priority vehicle light

DIAGNOSIS Diagnosis socket

The SPN error codes can be read out from the error memory of various control units using MAN-cats II (connection on diagnosis socket X200). The results are displayed on the MAN-cats display. View of socket X200, line side

\ Arrow in the centre points to Pin 1 Connector pin assignment - TGA:

Address

Diagnosis socket X200 Pin

Function

4

K-line KWP 2000

9

Negative potential

10

Voltage supply

Line number

From

16202

Via X2544 to the control units

31

31000

Earthing point, central electrical system X I 644 via X I 829

30

30009

Via X I 535 to fuse F412 / 10A

A211 1 F/3

Terminal

11

Voltage supply

15

16000

Via X I 833 to fuse F376 / 10A

12

Signal, alternator

W

59101

Alternator G I 02 pin 1

CES pin

- R021R03 and R071R08:

Address

Diagnosis socket X200

CES pin

Line number

From

16202

Via X I 908 to the control units

31

31000

Earthing point, central electrical system (item 92)

Voltage supply

30

30009

Fuse F412 / 10A

A211 1

11

Voltage supply

15

16000

Via X362 to fuse F376 / 10A

F/1

12

Signal, alternator

W

59101

Alternator G I 02 pin 1

Pin

Function

4

K-line KWP 2000

9

Negative potential

10

Terminal

DIAGNOSIS

FFR FFR FFR FFR FFR FFR FFR FFR FFR FFR

20 20 20 20 20 20 20 20 20 20

03233 03234 03235 03236 03237 03238 03239 03240 03241 03242

CAN databus: Astronic message TSCl-TE, byte 4 CAN databus: Astronic message TSCI-TE, byte 5 CAN databus: EBS message TSC1-AE, byte 1 CAN databus: EBS message TSC1-AE, byte 2 and 3 CAN databus: EBS message TSC1-AE, byte 4 CAN databus: EBS message TSC1-AE, byte 5 CAN databus: ZBR message AUX-ZBRI, byte 1 and 2 CAN databus: ZBR message AUX-ZBR1 , byte 3 CAN databus: ZBR message AUX-ZBRl , byte 4 CAN databus: ECAS message ECAS1, byte 6 to 8

DIAGNOSIS

take-off neutral switch indicates "Neutral"

activation valve is not activated

In-line engines

Publication No.:

81.99598-4322

MAN Nutzfahrzeuge Aktiengesellschaft Dachauer Str. 667 oder Postfach 50 06 20 80995 M~JNCHEN 80976 M ~ ~ N C H E N

Repair Manual 3rd Edition A 13 Reparaturanleitung A 13 (3. Ausgabe) Reihenrnotoren D 02 -1 D 08 - englisch -

Printed in Germany

ALLOCATION OF ENGINES TO VEHICLE SERIES / VEHICLE TYPES Engines for trucks

Series

Vehicle type (Trade name)

Chassis no. Starting from:

D 0226 MKFII 70 ............................................. F 9 ....................... xx.170 ...................... WMA4.. D 0226 MKF ....................................................F 9 ....................... xx.192 ...................... WMA4.. D 0824 D 0824 D 0824 D 0824

GF ...................................................... G 90 ....................xx.100 ...................... GF 01 ................................................ G 90 ....................xx.100 ...................... GF 02 .................................................G 90 ....................xx.100 ...................... GF 03 ....... Euro 1 .............................. G 90 ....................xx.100 ......................

D 0226 MFl125 .............................................. G 90 D 0826 GF 04 ....... Euro 1 .............................. G 90 D 0826 GFA 04 ..... Euro 1 .............................. G 90 D 0826 GF 03 ................................................ G 90 D 0826 GFA 03 ..............................................G 90 D 0826 GF 01 ................................................G 90 D 0826 GFA 01 ..............................................G 90 D 0826 GF ..................................................... G 90 D 0826 GFA ................................................... G 90

D 0824 D 0824 D 0824 D 0824 D 0824 D 0824 D 0824 D 0824 D 0824

FL 01 ....... Euro 1 LFL 04 ..... Euro 2 LFL 08 ..... Euro 2 LFL 07 ..... Euro 2 LFL 01 ..... Euro 1 LFL 05 ..... Euro 1 LFL 06 ..... Euro 2 LFL 02 ..... Euro 2 LFL 09 ..... Euro 2

D 0826 D 0826 D 0826 D 0826

LFL 03 LFL 10 LFL 06 LFL 02

WVML.. WVML.. WVML.. WVML..

....................xx.150 ...................... WVML.. ....................xx.150 ...................... WVML.. .................... xx.150 ....................xx.150 .................... xx.150 ....................xx. 150 .................... xx. 150 ....................xx.150 .................... xx.150

.............................. L 2000 .............................. L 2000 .............................. L 2000 .............................. L 2000 .............................. L 2000 ..............................L 2000 .............................. L 2000 ..............................L 2000 ..............................L 2000

...................... WVML.. ...................... WVML.. ...................... WVML.. ...................... WVML.. ...................... WVML.. ...................... WVML.. ...................... WVML..

.................xx.103 ...................... WMAL.. ................. xx.1 13 ...................... .................xx.1 13 ...................... .................xx.143 ...................... .................xx.153 ...................... ................. xx.153 ...................... ................. xx.163 ...................... ................. xx.163 ...................... ................. xx.163 ......................

WMAL.. WMAL.. WMAL.. WMAL.. WMAL.. WMAL.. WMAL.. WMAL..

..... Euro 2 .............................. L 2000 ................. xx.224 ...................... WMAL.. ..... Euro 2 .............................. L 2000 ................. xx.224 ...................... WMAL.. ..... Euro 1 .............................. L 2000 ................. xx.223 ...................... WMAL.. ..... Euro 1 ..............................L 2000 ................. xx.223 ...................... WMAL..

D 0824 LF 01 ....... Euro 1 .............................. M 90 .................... xx.152 ...................... WMAM.. D 0824 LF 03 ....... Euro 2 .............................. M 90 .................... xx.152 ...................... WMAM.. D 0824 LF 02 ....... Euro 2 .............................. M 90 .................... xx.162 ...................... WMAM.. D 0826 F 02 ...................................................M 90 D 0826 F 01 ................................................... M 90 D 0826 F ........................................................M 90 D 0826 TF .......................................................M 90 D 0826 LF 01 ...............................................M 90 D 0826 LF 05 ................................................. M 90 D 0826 LF 07 ....... Euro 1 .............................. M 90 D 0826 LFl217 ............................................... M 90 D 0826 LF 11 ....... Euro 2 .............................. M 90 D 0826 LF 13 ....... Euro 2 .............................. M 90 D 0826 LF 02 ................................................. M 90 D 0826 LF 06 ................................................M 90 D 0826 LF 08 ....... Euro 1 .............................. M 90 D 0826 LF ......................................................M 90 D 0826 LF 04 ....... Euro 1 .............................. M 90

....................xx.152 ...................... WMAM.. .................... xx. 152 ...................... WMAM.. .................... xx.152 ...................... WMAM..

.................... xx.1821192 ............... WMAM.. .................... xx.192 ....................xx.192 ....................xx.192 .................... xx.232 .................... xx.222 .................... xx.262 .................... xx.232 .................... xx.232 .................... xx.232 .................... xx.232 .................... xx.272

...................... WMAM.. ...................... WMAM.. ...................... WMAM.. ...................... WMAM.. ...................... WMAM.. ...................... WMAM.. ...................... WMAM.. ...................... WMAM.. ...................... WMAM.. ...................... WMAM.. ...................... WMAM..

DESCRIPTION AND DIFFERENTIATION CRITERIA The A 13 Repair Manual describes series D 02.. / D 08.. engines. This series has a modular configuration, i.e. larger or smaller engines with different power levels are built using the same design principles and, wherever feasible, use the same components. The most important shared features are twin cylinder heads and various add-on parts. The vehicle engines currently available are 4 and 6-cylinder engines, naturally aspirated engines and supercharged engines, each with different cylinder bores for D 02.. and D 08.. as well as various combustion processes. 1. Combustion process

There are three combustion processes. 1. The proven M-process in the D 02.. engines with direct injection through one-orifice nozzles into the central spherical combustion chamber in the piston (example: D 0226 MF).

2. The new process (without M letter coding) in the D 08.. engines with direct injection through four-orifice nozzles into the concave combustion chamber in the piston (example: D 0824 GF, D 0826 LF 01). -

Euro 1 engines have direct injection through five-orifice nozzles at an increased injection pressure of up to 295 bar into the concave combustion chamber in the piston (example: D 0824 GF 03, D 0826 LF 04).

3. Electronically controlled diesel injection (EDC) for Euro 2 engines. Euro 2 engines have direct injection through eight-orifice nozzles at an increased injection pressure of up to 320 bar into the concave combustion chamber in the piston (example: D 0824 LFL 04, D 0826 LFL 03). The injector nozzle of the first cylinder is equipped with a needle movement sensor for this purpose.

-

EDC stands for electronic diesel control. The electronic engine management system directly compares and monitors the actual values in relation to the stored nominal values. The values are continuously brought into line with the specified optimum nominal values. The version used is adapted to the engine type in each case. The most significant difference between this and the M-engines is the combustion process. Otherwise, the engines have largely identical configurations, meaning they are identical as far as repairs are concerned. This applies unless there is an express reference to differences during the repair sequence or in the technical data. 2. Supercharging There are four different supercharging methods. In D 08.. engines: 1. Turbocharging (T): The intake air required for the combustion process is precompressed by a turbocharger and fed into the cylinders through the intake manifold. Example: D 0826 TF 2. Turbocharging with intercooling (L): The intake air required for the combustion process is cooled to approx. 50 'C following precompression and then fed into the cylinders. Example: D 0824 LFL In D 02.. engines: 3. Turbocharging with resonance supercharging, without intercooling (C): The intake air required for the combustion process is compressed in a resonance system (tubes/chambers) for a second time following its initial precompression. Example: D 0226 MC 4. Combined supercharging with resonance system and intercooling (K): Combination of the characteristics of L and C. Example: D 0226 MKF 3. Crankcaselcrankshaft drive There are also differences between different crankcases: - The older D 02.. engines have crankshaft main bearings and fitted bearings of normal thickness. - The newer D 02.. engines (see 5.56 for information about engine numbers) have similar crankcases to the D 08.. engines. The D 02.. engines are fitted with thick-walled bearings in order to compensate for the differences in size, see 5.56 - 6. - Series production D 02.. and D 08.. naturally aspirated engines are built without replaceable cylinder liners.

CHANGESINEW FEATURES Mounting instructions The KSB function must be switched off before a fuel injection pump with a cold-starting aid (KSB) is fitted. This is because the start of pumping is moved towards "early" by max. 5" when the KSB function is switched on. KSB function setting when the pump is delivered - Use a suitable spanner (size 8) to brace clamping

piece @ and unscrew hexagon nut 0. @ Adjustment lever

- Move clamping piece @ into the release groove

of the guide piece @ by turning it through 90".

- KSB relieved The fuel injection pump can now be fitted.

-

-

Restore the preset early position after setting the engine. Do this by moving and turning clamping piece @. Use a suitable spanner (size 8) to brace the clamping piece and tighten hexagon nut @) to 3.5 k 1 Nm.

OIL PUMP

fT-k

Fittina the oil auma aear Place the oil pump gear (with its inside taper free from grease) onto the taper of the input shaft which must also be free from grease. Put on the washer, screw on the mounting nut and tighten it to the specified tightening torque. Fitting the timing chain housing, 5.54 - 3.

Installing the auxiliary oil pump

a.

Position the auxiliary oil pump Insert mounting bolts @ and tighten them to the specified tightening torque. Use mounting bolts @ and clips to fix on the second suction pipe @. Screw the suction pipe with banjo bolt 0, new locking fastener @ and new sealing rings @ onto the auxiliary oil pump. Tighten the mounting bolts of the suction pipe to the specified tightening torque.

?Mk4

REMOVING AND INSTALLING THE PCV VALVE Removing and installing (crankcase ventilation)

the

PCV

valve

PCV valves on engines being serviced after long periods in service must be replaced due to general wear and tear. For example: D 02.. engine .....................................................+

The seating of the PCV valve varies between the different engine types. Uncover PCV valve if necessary.

a

D 08.. engine with 3-cowl ventilation ...................-+

Release clamping bracket @ at the base of the PCV valve. Release clamping brackets @ on the air suction duct at the top of the PCV valve. and O-ring Remove PCV valve

a

a.

Fit a new O-ring @.

a

Position PCV valve and line it up with the intake line to the suction duct. Position hose section @ and tighten hose clamps @. Fasten clamping bracket @ at the base of the PCV valve.

I

FllTlNG A NEW BIG END BEARING

Checking the expansion of the bearing shells Removing a piston with its connecting rod, 5.61 Lay out the bearing shells together on a flat surface. Measure and note down expansion dimension "A". Measure and note down dimension "B". Expansion dimension = A - B

f

B I

Technical data 9.21 - 5

Note: Use bearing shells of the appropriate repair level when performing repairs on the crank pins.

Press new bearing shells into the connecting rod big end and the connecting rod bearing cover.

I

Important Note the installation position! The rod shell has a red paint mark on its side. Do not damage the running-in coating!

Lightly oil the bearing surfaces of the bearing shells. Installing a piston with its connecting rod, 5.61 - 3.

Note regarding D 02.. engines: Previously, it was a requirement that new connecting rod bearing bolts (expansion bolts) always had to be fitted during a repair because tightening these bolts permanently stretches them. However, tests have shown that an expansion up to a shank length (L) of 61 mm does not pose any problems. Connecting rod bearing bolts 51.90020.0190 can be re-used provided their shaft length does not exceed 61 mm. The shank length of a new connecting rod bearing bolt is 59.5 to 60.5 mm.

I

REMOVING AND INSTALLING OIL INJECTOR NOZZLES

Removing the oil injector nozzle Note: The oil injector nozzles can also be removed and installed without removing the crankshaft. The crankshaft has been removed here in order to give a better view. Unscrew oil pressure valve @ on oil injector nozzle @ and remove it. Remove the 011 injector nozzle together with the valve.

Checking the oil injector nozzle valve Use a small screwdriver to check whether the valve spring is still pressing valve piston against the valve seat. Fit a new oil injector nozzle valve if it is not. Note the opening pressure.

Installing the oil injector nozzle Position the oil injector nozzle and make sure the adjusting ball (arrow) on the oil injector nozzle body is placed in the hole provided for it (arrow).

Screw in the oil pressure valve and tighten it to the specified tightening torque. Check the spraying direction. The jet of oil must reach the piston crown without hindrance. Never attempt to straighten out oil injector nozzles which are bent.

@

I

CHECKING THE VALVE TIMING

Checking the valve timing Any twisting of the screwed-on camshaft drive sprocket can lead to serious engine damage. Consequently, check the valve timing to ensure the camshaft drive sprocket is seated correctly after any engine malfunction which could lead to twisting, e.g. failure of the air compressor. Precondition: The tappets must not be bent! Proceed as follows: - Fit the engine barring gear onto the flywheel housing. - Remove the valve covers. - Set the valve clearance of the 1st cylinder correctly.

Turn the engine to about 30" before TDC in the opposite direction to its direction of rotation. Place a dial gauge onto the inlet valve spring cap on the 1st cylinder with a slight preload. Zero the dial gauge. - Slowly turn the engine in its running direction and observe the needle on the dial gauge. - The intake valve opens as soon as the needle deflects. - Read off the degree scale on the flywheel and compare it with the timings on page 9.21 - 14. -

Note: Fitting one dial gauge each on the intake and exhaust valve head of the 1st cylinder makes it possible to check all valve timings and the valve lift by turning the engine further. Example: Control diagram for D 0824 LFL Values in degrees relate to the crankshaft angle.

a Turning direction of the engine @ Intake opens @ Exhaust closes @ Centre of intake cam @ Exhaust opens @ Intake closes @ Centre of exhaust cam @ Exhaust opening time @ Intake opening time

Note: Valve clearance and timings of various engines, see page 9.21 - 14.

REMOVING AND INSTALLING THE AIR COMPRESSOR IN D 02.. ENGINES D 02.. engine Removing the air compressor (with V-belt drive) Release the tension on the V-belt at the tensioning pulley and take off the V-belt. Separate the suction and pressure connection at the hose pieces. Remove the coolant hoses on a water-cooled cylinder head (see picture).

Note: Disconnect the hydraulic pump at the air compressor flange (arrows) if the vehicle has power steering. The lines can remain on the hydraulic pump.

Unscrew and remove the air compressor mounting bolts and lift the air compressor off the bracket. Remove the sealing rings for the pressurised oil supply and oil return.

Removing the air compressor bracket Unscrew and remove the mounting bolts. Remove the bracket with the tensioning pulley. Clean seal residue off the sealing surfaces. Removing, fitting, dismantling and assembling the tensioning pulley, 8.41

TABLE OF ENGINE SETTINGS

I

I

EURO1

I

1

EURO1

Emissions category Start of pumping Discharge pressure

21 6 ULLH 33 S 119

I A

/x

!-J

51.1 01 02-0216 51.1 0101 -7339

322

1 1

153

1

339

If25 40

I

- -

51.1 0102-0202 51.1 01 01-7349

DLLA 78 P 322

1 1

Jet bear. with nozzle

DLLA 134 P 180

1 1

0 433 175 053

1

0 433 171 159

1

Manufacturer's no.

Nozzle name

700f 25

800530

Idling speed

2840

2600

Setting for inj. cut-off

- - - -

1

I

2700

speed min./max. Idling speed

*I

-

Inj. cut-off Ispeed A1J - 3105

min./max. K-value A l 30

11103-7158

51.1 1103-7243

MAN no.:

RQV

RQV

Governor

1181160/24(

1 I4115512400

EURO 1

EURO 2

EURO 2

4-1

8- 1

2651250

27(

51.101 02-0202

51.

1

-

51.1 1103-7217

1I4115512400

DLLA 134 P 180

Fuel injection pump

I

EUROl

I

Emissions category Start of pumping Discharge pressure

2701250 223

DSLA 154 P 492

51.1 0102-ULZJ

1

DSLA 154 P 492

1

DLLA 134 P 180

1

Nozzle name

0 433 175 085

0 433 171 159

Manufacturer's no.

800f 30

800f30

Idling speed

2650

2600

Setting for inj. cut-off

27;

2750

2700

speed min./rnax.

80C

800+1 OC

800+

Idling speed AU

Lu-w

261,

3~;c;n

355n

Inj. cut-off speed AU

2780

2770

min.1max.

1.4

0.7

K-value AC

2 F 1200..

-

-

PE.

A320.

PES 4P120A320

VE 4112 F 1200..

Fuel injection pump

51.

295

51.1 1103-7469

51.1 1103-7243

MAN no.:

RQ

RQV

Governor

RQ

I

TABLE OF ENGINE SElTINGS

114115512700

10 51 . l u102-0199

I 51. I u l u z - u z l /

51 .I 0101-7305

51.1 0101 -7333

DLLA 140 P 175

DLLA 35 S 1190

kW1h.p.lrpm

FAV 2

Emissions categoryart of p unping ~

i

scharge pressure

s l .I ulu2-0217

i20

11011 5012700

1

1

51.10101-7333

51.1 0101-7339

Nozzle Jet bear. with nozzle

DLLA 35 S 1190

DSLA 78 P 322

Nozzle name

0 433 271 520

0 433 175 053

Manufacturer's no.

585f35

585k35

Idling speed

51.10102-0216

Setting for in~.cut-off speed min./max.

1 1.5

31(

t

Idling speed AU

600+100

1.8

I~1

VE 611 51 .I 1l u z - / 8 / 3

11lu3-/032

RQV

RQV

Replac

Up to engine no. 6579000..

51 1 1 1u ~ - / t l b 3

Inj. cut-off !

J

3105

min./max.

-

1.2

K-value Ab

VE 611 1 F 1350..

Fuel injection pump

51.1 1103-7159

MAN no.:

RQV

Governor Remark:

From engine no.

...6579001 ....

-

I %issions categoryart of pur scharge Ipressure

DSLA78P322

1 nlLA140P175 33 171 154

1 1

DLLA35S1190 0 433 271 520

I 1

585f 35

I Nozzle I Jet bear. with nozzle DLLA35S1190 0 433 271 520

1 1

Nozzlename Manufacturer's no. Idling speed

585k35

Setting for inj. cut-off

I f 4 n g speed AU . cut-off ! n./max.

I RQV

I

RQV

1

VE 611 1 F 1350..

(

VE 611 1 F 1350.. 51.1 1103-7032

(

51.1 1103-7157

/

RQV

I

RQ From engine no. ...6579001....

Up to engine no. ...6579000....

RA-A13

1 I I

Fuel injection pump

MAN no.: Governor Remark:

9.13 - 9

I

TABLE OF ENGINE SETTINGS

(

FAV E

EURO 1

EURO 1

1

I

EURO 1

14-1

Emissions category tart of pumping

2651250

ischarge pressure

2651:

51.1 0102-0202 51.10101-7349 DLLA 134 P 180 0 433 171 159

1 1

1

585f 35

DLLA 134 P 180 0 433 171 159

1 1

1

585f35

Nozzle name Manufacturer's no. Idling speed Setting for inj. cut-off speed min.1max. !d AU

-

j. cut-off speed A\ in./max.

-

2.3

.value A1

-

PES6MW1001321

Fuel injection pump

51.1 1103-7253

MAN no.:

RQV

Governor Remark

Replaced by

--

-

-

162122012400

162122012400

191126012300

EURC

EUIRO 2

EURO 2

5- 1

lo after

160121712200

d

kW/h.p.lrpm Emissions category

15-1

Start of pumping

2701250

2651250

Discharge pressure

51.1 0102-0223

51.1 0102-0223

51.1 01 02-0202

Nozzle

51.1 0100-7364

51.10101-7364

51.1 01 01-7349

Jet bear. with nozzle

,LA 154 P 492

DLLA 134 P 180

Nozzle name

33 175 085

0 433 171 159

Manufacturer's no.

585f35

Idling speed

2701250

DSLA 585f35

630f30

600f 50

2580 2680

2500 2560

'

Setting for inj. cut-off speed min./max.

630530

600+

ling spee

2520

i. cut-off Ispeed A1J

2650

2310 2530

m~n.lmax.

1.18

2.5

K-value AC

PES6H1101320..

PES6MW1001320 Fuel ~njectionpump

1 1103-7461

5 1.I1103-7482

51.1 1103-7022

MAN no.:

IV

------

RQV

Governor

Silent engine

Remark:

PES6P120A320..

Wlth RQ 51.1 1103-7330

PESGP120A320..

(Idlingltop speed governor)

-

STANDARD TORQUE TIGHTENING VALUES 7.2

Tightening torques in accordance with the M 3059 works standard

Bolt connections for which no torques are specified. with the exception of those that are less important or used for tacking purposes. should always be tightened using either the torque wrenches generally found in workshops or precision bolt tighteners. The actual torque values should not deviate from the specified values by more than +I 5%.

Notes on the use of the tables below .

-

In the case of property class pairings other than those specified. use the tightening torque of the component with the lower property class (e.g. if the bolt hash a property class of 8.8 and the nut a property class of 10. use the tightening torque given in the column headed 8.8). If you are fastening a component with a slot to one with a hole. tighten from the side with the hole.

Nutslbolts with an external or internal hexagon and a head without a collar or flange Thread size x pitch

Property classes in Nm (boltlnut)

I

SPECIAL TOOLS

Fig. no.

4 -

Name

MAN no.

Sectionipage

[I] [I . 11

Dial gauge for setting the start of pumping ............................... 08.71000.1 205 Extension for [I] ........................................................................ 08.71 075.0507

2.1 1 .1 2.1 1 .1

[2]

Adapter for [I] ........................................................................... 80.99605.6007

2.1 1 .1

[3]

Special spanner (size 17) for injection pressure lines ............... 80.99603.0025

2.12 .3

[4]

Illuminated indicator for setting the start of pumping ................. 80.99605.6002

2.21 . 1

[5] [5.1]

Locking pin for fuel injection pump camshaft ............................ 81.1 1523.0042 New version, including Euro 2 ................................................... 80.99605.0217

2.21 . 1

[6]

Socket for jet bearing forcing bolt D 02 .................................... 08.06141 .9062

2.31 - 1

[7]

Grooved nut spanner for jet bearing forcing bolt D 08 .. .Previous grooved nut spanner ................................................ 80.99603.0121 . New = 3 grooves, open for needle movement sensor ............ 80.99603.0240

2.31 .2

[8] [8.1]

Inertial puller for injector nozzles ............................................... Adapter for [8] ....................................................................

80.99602.0011 80.99602.0059

2.31 .1

[9]

Mounting device for injector nozzles ........................................

80.99606.0008

2.32 - 2

[I 01

Socket for injector nozzle union screw connection ................... 80.99603.0024

2.32 - 3

[I 11

Puller for V-belt sheavelflange on water pump ......................... 83.09143.6060

3.22 .1

[I 21

Press-in bush for water pump cassette ring .............................. 80.9961 7.0091

3.22 .3

[13]

Press-in bush for water pump bearing shaft ............................. 80.99635.0008

3.22 .4

[14]

Press-in plate for water pump vane impeller ............................. 80.99614.001 6

3.22 .4

[I 51

Oil filter wrench .........................................................................

80.99606.0343

4.10 .1

[I 61

Press-in device for oil pump shaft ............................................. Comprising: Support liner .............................................................................. Spacer bush ..............................................................................

80.99604.0055

4.32 .3

80.99604.0056 80.99604.0057

SPECIAL TOOLS

SPECIAL TOOLS Fig. no.

MAN no.

Name

Sectionlpage

u

[I 71

Internal extractor for clutch pilot bearing ...................................

[I 81

Counter support for [I 71 ............................................................ 08.9961 5.0005

[I91

Press-in pin for clutch pilot bearing ........................................

[20]

Extractor hook ........................................................................... 80.99602.0127

[21]

Impact puller for [20] .................................................................

[22]

Handle for all press-in plates ................................................80.99617.0129

[23]

Press-in plate for crankshaft sealing ring. front 02....................................................................................... . D 08.......................................................................................

[24]

Press-in plate for crankshaft sealing ring. flywheel end ............ 80.99614.0032

[25]

Torque angle gauge for bearing bolts .......................................

80.99605.0010

[26]

Piston ring clamp. universal ....................................................

80.99625.0001

1271

Slip-on sleeve 0 108 mm ..........................................................

83.09144.0057

.D

08.9961 5.1400

80.99617.0059

80.99602.0016

80.99614.0033 80.99617.0073

Engine barring gear ............................................................... [28] [28.1] Gear ratchet for [28].................................................................

80.99626.6006 80.99627.0001

[29]

Dial gauge holder ......................................................................

80.99605.01 72

[30]

Piston ring compressor pliers .................................................... 83.09144.6090

[31]

Cylinder liner extractor device. complete .................................. 80.99602.0019

[32]

Extractor plate 0 102 mm ........................................................ 0 107.8 mm .....................................................

.

80.99602.0097 80.99602.0123

Note: There is a complete catalogue of MAN SPECIAL TOOLS This catalogue contains all special tools that MAN supplies for maintenance and repairs to MAN trucks. buses and engines . Order no . 81.99593.8062, order from the central spare parts warehouse .

In-line Engines D 02.J D 08..

Publication No.:

81.99593-4032

MAN Nutzfahrzeuge Aktiengesellschaft Dachauer Str. 667 oder Postfach 50 06 20 80995 M ~ ~ N C H E N 80976 M~JNCHEN

Repair Manual I st Supplement A 13 (3rd) Reparaturanleitung A 13 (3. Ausgabe) 1. Nachtrag Reihenmotoren D 02.J D 08.. - englisch Printed in Germany

1st Supplement to the Repair Manual A 13. 3rd Edition Information on inserting this supplement into the existing manual. Please use all the pages in this supplement to replace the corresponding pages in the 3rd edition of the Repair Manual A 13 or add them as new pages. The page numbers are identified with the index letter "a" so you can subsequently identify which pages have been exchanged.

Example: Previous page number: 1.20 .1, page number of replacement page: 1.20 .1a. Exchange the following pages

1.00 .1 to 1.00 .3 ....................................deleted Title page and 1.10 .2 .................................... by ............................................. T i t Page add ............................................ 1.15.la 1.30 .1 to 1.30 .3 .................................... by ............................................... 1.30 .1a 2.11 - 1 to 2.11 - 3.................................... by ............................................2.11 - l a 2.13.1 to 2.13.6 .................................... by .............................................. l a add ........................................ - l a add ............................................ 6 . l a 5.1 1 .1 ................................................by ............................................. 5.11 .l a 5.52 .1 ................................................ by ............................................. 5.52 .l a 6.21 .1 to 6.21 .2 .................................... by ............................................6.21 .l a add ........................................ 6 . 2 .1a 6.33.1 to 6.33.2 .................................... by ...........................................- l a add ............................................ - l a 7.13.1 to 7.13.2 .................................... by .......................................... 7.13. l a add ............................................ 7.14. l a add ............................................ - l a 7.23.1 to 7.23.5 .................................... by ..............................................- l a 7.51 .1 to 7.51 .4 .................................... by .............................................. 7.51 .l a 8.13. 1 to 8.13.7 .................................... by ............................................. 8.13. l a 8.51 .1 ................................................by ............................................. 8.51 .1a 9.00 .1 to 9.61 .1 = blue pages .............. by ..................... blue pages = 9.00 .1a 9.71 .1 to 9.72 .2 = pink pages .............. by ..................... pink pages = 9.71 .1a

and 1.10 .2a to 1.15.3a to 1.30 .3a to 2.11 - 3 a to 2.13. 10a to 2.15.4a to 2.16.2a

to

6.21 .2a

to to to to to to to to to to to

6.33.2a 6.35.5a 7.13.2a 7.14.2a 7.15.2a 7.23.7a 7.51 .4a 8.13.7a 8.51 .2a 9.61 .l a 9.72 .2a

ADJUSTING THE VALVE CLEARANCE Adjusting the valve clearance Do not set the valves unless the engine is cold. (Max. cooling water temperature 50 "C.) Remove the valve covers.

IMPORTANT Residual oil may leak out. Treat used oil as hazardous waste. Comply with the safety regulations for preventing environmental pollution. 4-

i e engine barring gear [28] can be fitted on newer engine types.

Diagram of cylinder order and valve arrangement in 4-cyl. engines. I II

Fan end Power output

6

Exhaust valve

& Intake valve

Setting the valve clearance in 4-cylinder engines: Turn over the engine until the rocker arm has moved the cylinder to be set into the unloaded position. The rocker arms of the synchronous cylinder are then in overlap.

a

Rocker arm in overlap with cylinder:

@

Setting the valve clearance with cylinder:

Firing sequence: 1 - 3 - 4 - 2 Valve clearance (with the engine cold) with D 02..

Intake................................... 0.20 mm Outlet ................................... 0.35 mm

with D 08..

Intake/outlet ......................... 0.50 mm

+

I

SElTING THE EVB VALVE CLEARANCE D 08.. engines with EVB EVB = Exhaust Valve Brake The system increases the braking effect of the engine through holding the exhaust valves open by a gap during the engine braking procedure. Check the valve clearance at the previously normal intervals and adjust it if necessary. Do not set the valves unless the engine is cold. (Cooling water temperature below 50 "C.) As far as the intake valve is concerned, there is no difference between engines with EVB and those without EVB. Set screw 1 @ Locknut 1 Tightening torque ...................50 Nm @ Counter-holder Tightening torque ................... 60 Nm +90° @ Set screw 2 @ Locknut 2 Tightening torque ...................40 Nm @ Depressurisation hole (oil drain) @ Piston (cut open) @ End of the valve stem @ Rocker arm (cut open) @ Pressurised oil hole (oil supply)

Checking the exhaust valve clearance 1. Set the piston of the cylinder to be checked to ignition TDC. 2. Turn adjuster screw 2 @ in the counter-holder back as far as possible without using force.

3. Push the rocker arm downwards - e.g. using a screwdriver - as often as required (at least 3 times) until no more oil emerges from the depressurisation bore. (All the oil must be forced out of the piston space.) 4. lnsert a 0.55 mm valve feeler gauge between the piston @ and the end of the valve stem @. If the 0.55 mm valve feeler gauge can be inserted, continue from the setting section. Continue checking if the 0.55 mm valve feeler gauge cannot be inserted. 5. Insert a 0.50 mm valve feeler gauge between the piston @ and the end of the valve stem @. If the 0.50 mm valve feeler gauge cannot be inserted, continue from the setting section. Continue checking if the 0.50 mm valve feeler gauge can be inserted 6. Push a 0.35 mm valve feeler gauge between the piston and valve stem. Press down the rocker arm using a screwdriver until the piston reaches the stop, thereby forcing all the oil out of the piston space.

7. Hold the tappet pressed down and screw in adjuster screw 2 @ until the valve feeler gauge is clamped. 8. Set a 0.35 mm valve clearance by loosening adjuster screw 2 @, but only so far as it is possible to pull out the valve feeler gauge against moderate resistance. Tighten locknut 2 @ to 40 Nm. 9. Check: There must be play on the push rod.

TABLE OF ENGINE SElTINGS

n

*Tissions bef. TDC

art of purnping

0 bar

;charge 13ressure t bear. with nozzle

50 bar

51.1 0102-0202 DLLA 134 P 18(

I L L I ~I

I

I

Z/OU

ing speec . cut-off s m~n./rnax.

1.4

K-value AU

VE 6112 F 1200..

Fuel injection pump 4N no. -

51.1 1103-7022

51.1 1

RQV

RQV

16" 20.5" bef. TDC

la1 he

er's no. ing speec

0 433 171 159

PES6MW1001320

category

'

1

7" - l o bef. TDC

/

14" - l o bef. TDC

I 5" -lo bef. TDC

-

I Start of pumping

2651250 bar

2651250 bar

263250 b:

2651250 bar

Discharge pressure

51.1 0101-7349

51.1 0101-7349

51.1 0101-;

51.1 0101-7349

Jet bear. with nozzle

--

51.1 0102-0202

1

51.1 0102-0202

1

51.1 0102-0202

1

51.1 0102-0202

DLLA 134 P 180

DLLA 134 P 180

DLLA 134 P 180

DLLA 134 P 180

0 433 171 159

0 433 171 159

0 433 171 159

0 433 171 159

585535

585

1

VE 6112 F 1200..

ing speec

--

252

2520

I

1

PES6MW1001321 VE 611 2 F 1200..

51.1 1103-7165

51.1 1103-7110

1

51.1 1103-7165

51.1 1103-7199

DA

RQ'

I

RQ

RQV

I 1 U

with RC 51.1111

with RQ 51.1110:

Nozzle Nozzle nan Manufactur-. - . .-. ing speec3

58553

600

PES6MW1001321

1

] In]. cut-off speed AU

I

-

Fuel iniection pump

I MAN no. _ I

-

-

TABLE OF ENGINE SETTINGS

9 sure 3r. with n

-- 600+1O(

600+

Idling : ;peed AC

252C

Inj. cut-off spee min./m-... K-valuc3 AU

276C 1.O

101321 51. RC -

N1001321

-

wit,, ,,, 51.1 1103-7267

wltn HU 51.1 1103-7301

6-Zyl. RP 43

Fuel injection PI

51.1 1103-7559

51.1 1103-7529

RQ with RQ 51.1 1103-7558

EDC-MS5

MAN no. Governor

PESl

1201

Remark:

* NBF = Needle movement sensor

1621220/2400

162122012400

162122012A00

162122012

kWlh.p.1rpm

Euro 2

Euro 2

Euro 1

Euro 1

Emlss~onscategory

'4' - l o be4 TnP

Start of ~ , u m ~ gi n Discharge pres:sure

-

lo bef. Tnr

%f. TDC

-

bar

27(

651250 t:

250 bar

51.1 0100-7

51.1010 0-7364

51 .I 0101-73L

51.1 0102-0223

51.1 0102-0223

51.1 0102-0202

51.1 0102.

DSLA 154 P 492

DSLA 154 P 492

DLLA 134 P 180

DLLA 134

"33 175 085

0 433 175 085

0 433 171 159

0 4 3 3 171

)+30

630+30

5855

585f35

6002100

6002100

12100 2530 2730

- 630+100 -

1.4

1 .U

PES6P120A320..

PES6P1

RQV with RQ

- -

1.101 01-7349

133

)p speed

Jet bear, w~thnozzle Nozzle Nozzle name Manufacturer's Idling speed

- Idling speed AC Inj. cut-off spee ax.

254C 273C

1.O

>

1

K-value HU

6MW1001321

PES6MW1001321

Fuel injection PIumP

1 103-7331

51.1 1103-7384

MAN n

RQV (Idlingltop speed governor)

Governor Remark:

RQ with RQ 51.1 1103-7332

TABLE OF ENGINE SETTINGS

17" +_I " bef. TDC

18" -1" bef.

Euro 1 16" - l o bef. TDC

175 bar

190/175 ba

1901175 bar

Euro 1 4" -'I" bef. TC 2651250 bar

L 7

51

n i:ar

1I

with RQ 51.1 1103-7036

Remark:

i Euro 1

bef. TD( 61 1 n101-7349

Governor

-

4011 901;

iuro 1

FAV 2

MAN no.

103-7035

-.

nissions category

Y?

" bef. TC

50 bar

3rt of purnping

1

" I .

Di!;charge Ixessure -

Jet bear. with nozzle

1 0102-02

DLLA

DLLA 1

~zzlenan ,er's no.

cnn

I

.I nn

cnnlinn

ing speec

' 500+100

/

600+1nn

. cut-off 5 n.1max.

2760 2.5 PES6h 51.1 1103-7240

21

PESGMW1001321 VE 6/12 F 1200.. c 4

iiin.3

51.1 1103

K-value AU

2.3

2.3

PES6

321

51.1 1103-7219

7"ni

Fuel iniectic3n pump MI

-.

vith RQ i1.11103-7199

with R Q 51.1 1103-7218

Gc Remark:

An

Piston (c D 08.. Mahle, measured 22.7 mm above tli e bottorn edge o.f the pist1 Normal dimension ................... .......................................... . . ~versizestage 0.5 mm .................... I

4lcan, mt2asured above t tte bottorri edge of the piston @ Norrnal dime1 ...................................................................................... wersize stage 0.5 I'iston-in- cylinder clearanc~ . . . . . ............ h e a r 11m1t .............. .............. Piston protrusion I 2p edge I~f crankc

Piston compression level 3 08.. Normal dime1ision ..... Undersize I I I

108.. supercharged* Wan, measured 13 mm above the bottom e Normal dimension ................... 1st oversize stage 0.5 mm ......

ie piston

Schmidt, measured 12 mm above the bottom edge of the ~ i s t IbLJI ~Normal dime1 'iston-in-cylinder Wear limi Piston prc

c;ladl dl lc;!

.............. ~p edge of crankc

Piston compression level e> 3 08.., superchar~ led Normal dirnerision ..... Undersize II

3ore for gudgeon pin ........ 3udgeon pin diameter .................... .............., .............. 'iston weight difference pe!r set in cme engirle, max. ,

Uote:

I ne Manle plsron nas Deen replacea ~y Hican or scnrnlar plsrons. Either Alcan or Schmidt pistons can be used.

"JSTMENT VALUES

REFERENCE TORQUES

I torque!;for ins1tallation to Works Stand; ..

With the exception of subordinate or tacking connections, screw connections without specially prescribed tightening torques should always be tightened using standard workshop torque wrenches or precision nut runners. The torques applied should not differ from the specified tolerance values by more than k15°/0.

Notes about using the ta - For strength pairings other than those glven, use the tlghtenlng torque tor the part In the lower strength

-

-

,mined from class (e.g. bolt in strength class 8.8, nut in strength clas: the 8.8 column). When tightening a part with a slot onto a part with a round nole, worK trom rne slae wltn tne round hole. Do not tighten Ripp bolts and n ilts onto :;lots. Wherever possible, alvvays w o,k~ on thc! side of the harcler material wheri tightening soft (:omponents against hard ones. .. . . Always use washers to protect light alloy metal surfaces in conjunction with hexagon bolts and nuts. Do not tighten Ripp bolts and nuts on light alloy metals. Bolts with a collar or flanged head may only be tightened using rings spanners or sockets due to the low h~i"h t of the head flank-

Nominal assemt,ly tighte!ning torques MAfor screw connections with a smooth bearing surface I

I Thread si; x pitch

Strength classes (bolt Inut) in Nm External or interrial hex,agon smooth 10.9110

Collar or flange head .9/12

10.9110

MAN Nutzfahrzeuge Aktiengesellschaft Dachauer Str. 667 or Postfach 50 06 20 80976 MUNCHEN 80995 M~JNCHEN Repair Manual - A 13, 3rd Edition incl. 1st Supplement D 02.. / D 08.. In-Line Engines - English -

Publication No. 81.99598-4322 Printed in Germany

Common-rail In-line Engines

Copy deadline: 12.2004

81.99598-6282 MAN Nutzfahrzeuge AG Dachauer Str. 667 80995 Miinchen oder Postfach 500620 80995 Munchen

I st edition

Repair Manual A23 Reparaturanleitung 1423, Reihenmotoren Common Rail D 0834 LF40 D 0834 LF41 D 0834 LF42 - Englisch -

Printed in Germany

Repair Manual A23 1st edition

Common-rail In-line Engines

Special tools

Pressing off the impeller

Removing the coolant pump hub

Pressing out the coolant pump slide seal ring

Pressing in the coolant pump slide seal ring in conjunction with: Installer sleeve [6]

Pressing in the coolant pump slide seal ring in conjunction with: Plug-on handle, short [4] Installer sleeve [6] Installer sleeve

[GI ,,

/p\,

Q

,,,,,./

,)

Pressing in the coolant pump slide seal ring in conjunction with: Plug-on handle, short [4] Disc [5] Feeler gauge

[71

Pressing on the impeller

-I

Angle extension

1331 -.,, ,'.'. /

j+~.>

,/,'

), '$

7,1,

d.-: -'$st-.g.$

Ct'

-

2

C ,-

fi;$

. .

Fitting the heater element

Slide new fuel pre-filter element (3) into fuel service centre (4) Screw in filter end cap with new O-ring and tighten to prescribed torque, see Technical data, page 87 Removing the fuel pre-heater Removing the heater element

md2876gcb12

Unscrew mounting bolts (1) Pull heater element (2) out of fuel service centre (3)

Slide heater element (2) with new O-ring into fuel service centre (3) Position the mounting bolts (1) and tighten to prescribed torque, see Technical data, page 87

FITTING AND REMOVING THE FLAME START DEVICE

(1) (2) (3) (4)

Fuel pre-filter Hand-priming pump Fuel service centre Mounting bolts, solenoid valve

(5) Solenoid valve (6) Fuel line (7) Flame glow plug

Technical data Flame glow plug ....................................................... M32x1.5 ........................................................ max. 25 Nm Mounting bolts, solenoid valve ................................. M6x12-8.8 .............................................................. 9 Nm Fitting for solenoid valve .......................................... 1 0 x 1 .................................................................. 15 Nm Electrical connection, flame glow plug ..................... M4 ......................................................................... 5 Nm Line to glow plug ..................................................... 1 0 x 1................................................................... 10 Nrn

Attaching the fuel lines

Position fuel line (2) at fuel service centre without strain Screw banjo bolt (3)through fuel line (2) into solenoid valve (1)and tighten to the prescribed torque, see Technical data, page 93 Position fuel line (5) without strain at solenoid valve (I) and flame glow plug, and tighten Position mounting bolts (4) and tighten to prescribed torque, see Technical data, page 93 Fitting the flame glow plug

Screw flame glow plug (1) into intake pipe Align flame glow plug and attach fuel line Tighten flame glow plug to prescribed torque, see Technical data, page 93 Attach cable

FIlTING AND REMOVING THE CHARGE AIR PIPES

Charge air manifold to charge air cooler Mounting bolts O-ring Charge air pipe O-ring

(6) (7) (8) (9) (10)

Charge air manifold from turbocharger O-ring Shaped clip Turbocharger Oil filter module

Technical data Mounting bolts (2) .................................................... 8 170-8.8 .......................................................... 23 Nm Mounting bolts (2) ...................................................M8x40-8.8 ........................................................... 23 Nm Shaped clip .............................................................. 8 .......................................................................... 7 Nm

in combination with: assembly tool [68] Fitting and removing the valve springs 80.99606-0588 in combination with: assembly tool 1681 Fitting and removing the valve springs

in combination with: assembly tool [758] Fitting and removing the valve springs

Lifting out the valve keepers

Assembling the cylinder head Fitting the valves

After being forced off, the valve keepers (1) stay inside the assembly tool (2) and are lifted off the valve stem F

Removing the valves

-

Note The exhaust valves (2) have a larger recess in the valve head and areg re irl in diameter.

1 I

Slide the exhaust valves (2) and intake valves (3) into the valve guides of the cylinder head (1) Attaching holder for valve lifter

Unscrew guide sleeve and remove valve spring retainer (2) and valve spring (3) from valve Remove special tool from cylinder head Turn the cylinder head over and remove washers and valves The same procedure is used for all the valves. The base plate and guide sleeve must be transferred to each valve in turn

4

CAUTION Valve heads will be damaged if valve keepers with one ring are used. Only valves, valve keepers and valve spring retainers with a three-ring retaining collet may be fitted. The valve spring retainers feature three visible raised areas.

Clamp cylinder head (2) on assembly plate (1)

[651 Fix base plate with notched piece (4) from tool kit [68] through the cylinder head into the assembly plate (1) using a hexagon bolt (3) Screw guide sleeve (5) for assembly tool into base plate (4)

ASSEMBLING AND DISMANTLING THE OIL PUMP This comprises Draining and refilling engine oil, Maintenance Manual Fitting and removing the oil sump, page 197 Fitting and removing the oil pump, page 189

(1) (2) (3) (4) (5)

Mounting bolts, oil pump cover Oil pump cover Oil pump gears Oil pump housing Mounting bolts, oil pump cover

(6) (7) (8) (9)

Drive gear Mounting bolt, oil pump Pressure limiting valve (DBV) Mounting bolts (pressure limiting valve)

Technical data Mounting bolts, oil pump cover (1) ........................... M8x55-8.8 ............................................................ 22 Nm Cheese-head screws, oil pump cover (5) ................ M8x55-8.8 ........................................................... 22 Nm Backlash, drive gear - oil pump drive gear ................................................................................ 0.5 + 0 / - 0.1 End float, oil pump gear ........................................................................................................ 0.050 - 0.128 mm

Special tools

[I461

Gauge holder base plate

80.99605-0172

in combination with: dial gauge [595] Measuring end float of oil pump gears

13641

Press pin

80.99617-0029

Forcing off the oil pump drive gear

[5951

Dial gauge in combination with: gauge holder base plate [I 461 Measuring end float of oil pump gears

08.71 000-3217

ASSEMBLING AND DISMANTLING THE OIL PUMP Dismantling the oil pump

Assembling the oil pump

Removing the oil pump cover

Forcing the drive gear on

Place oil pump housing (3) and oil pump gears on spacer blocks (4) Force on drive gear (2) using a suitable press pin (1) until the backlash is correct, see Technical data, page 191

Unscrew mounting bolts (1) for oil pump cover (2) from the oil pump housing (3) Unscrew mounting bolts (4) through the bore in the drive gear (5) Remove oil pump cover Forcing off the drive gear

Measuring the backlash

md2876bcc06

Place oil pump (5) on spacer blocks (4) Using a press pin (1) [364], force the oil pump gear (2) out of the drive gear (3)

•

• a

Place the gauge holder (1) [I 461 and dial gauge (2) [595] on the oil pump gear (3) Set the dial gauge to zero Place the tip of the dial gauge on the drive gear (4) and measure the amount of backlash between it and the oil pump gear (3), see Technical data, page 191

Fitting the vent line for the air intake

Attach vent line (2) with union nut (1) on air intake Slide retaining clip ( 3 ) on to vent pipe using angular clamping pliers [771] Slide vent line on to connecting pipe for oil separator (4) and fasten with a hose clip ( 3 ) Fitting the vent line to the flywheel casing

Slide retaining clip (2) on to vent pipe ( 3 ) using angular clamping pliers [771] Push vent pipe ( 3 )on to ventilation manifold and fasten with retaining clip ( 2 ) Fit banjo bolt (4) into flywheel casing with new seals Tighten banjo bolt to the prescribed torque, see Technical data, page 239

FITTING AND REMOVING THE FLYWHEEL CASING This comprises Fitting and removing the starting motor, page 53 Fitting and removing the flywheel, page 201

(1) Mounting bolts, flywheel casing

(2) Flywheel casing

Technical data Mounting bolts (washer head bolts) (1) ....................M10x54-12.9 ........................................................ 75 Nm Mounting bolt, thrust washer ....................................M8x8.4-12. ......................................................... 40 Nm Consumables Thread-locking adhesive .................................................................................................................

Loctite 648

Important information CAUTION If the PTFE seal comes into contact with oil or grease before being fitted, it will be unusable.

Clean oil and grease from the crankshaft and fitting tools before assembly.

Special tools

Extractor assembly

[831

&&1 ,3

80.99601.6018

Extracting cylinder liner

@J

[I461

Gauge holder base plate

80.99605.0172

in combination with: dial gauge [595] Measuring'cylinder liner protrusion Measuring plate in combination with: measuring combination 11691

in combination with: gauge holder base plate [I 461 Measuring cylinder liner protrusion

80.99605.0195

Trucknology Generation A (TGA)

Maintenance Manual

MAN Nutzfahrzeuge Aktiengesellschaft Dachauer Str. 667 oder Postfach 50 06 20 80995 M~JNCHEN 80976 M~JNCHEN

-

Printed in Germany

Wartungsanleitung WA 74 (3.) Trucknology Generation A (TGA)

Maintenance Manual WA 74* (3.)

Trucknology Generation A (TGA)

ENGINE D 0836 LF, FOUR-VALVE - WITH EVB CHECKING THE VALVE CLEARANCE (alternative method) -

Alternative method for adjusting valve clearance in D 0836 engines This alternative method enables all valves to be checked and adjusted in just two crankshaft positions. The method described here can be used as an alternative to the usual method already described.

Adjustment Fit the engine barring gear on the flywheel housing (+) (see page 1) Turn the crankshaft until it reaches the nearest TDC position so that either cylinder 1 or cylinder 6 is at ignition TDC 6 valves can be adjusted in this position Then turn the engine 1 more revolution so it reaches TDC again The remaining 6 valves can now be adjusted Cylinder 1 or cylinder 6 must be exactly at the TDC mark.

If cylinder 6 is at ignition TDC (= cylinder 1 in overlap), adjust:

0 Exhaust valves and a intake valves

k6

Intake valves

Exhaust valves

If cylinder 1 is at ignition TDC (= cylinder 6 in overlap), adjust:

a Exhaust valves and 0 intake valves @

Intake valves

4

$

Exhaust valves

Remove the engine barring gear Fit the cover on the flywheel housing.

ENGINE D2866 LF, D2876 LF, DO836 LF CHANGING ENGINE OIL AND FllTlNG A NEW FILTER Park the vehicle on a flat, level surface Switch off the ignition

Draining the oil (with engine at operating temperature) Note: A new oil filter is also fitted each time the engine oil is changed. When the oil is changed, you may notice that a quantitv of used oil (0.3 litres when ECAS is at normal-level and vehicle is parked on the flat) remains in the oil sump overflow area. This is due to the shape of the oil sump. The actual quantity depends on how far the vehicle is lowered at the rear. If ECAS is fitted, you should raise the rear of the vehicle as far as possible when changing the oil so that all of the used oil can flow out. Note: The vehicle must be standing on a flat, level surface when the oil level is measured! If necessary, switch ECAS (electronically controlled air suspension) to the normal level, see sections 3.00 and 3.1 013.1 1 "ECAS" in the Operator's Manual The engine oil level falls when the rear axle is lowered and rises when the rear axle is raised. Tilt the cab Put an oil pan or similar underneath Unscrew the oil drain plug @ at the oil sump (example illustrated) You must comply with the notes on safety regarding the treatment of used oil and the disposal of oil filter elements, see section 0.50 "NOTES ON SAFETY AND ENVIRONMENTAL PROTECTION"! Drain the used oil from the oil sump drain hole

INTAKE SYSTEM Checking the water drain valve vvater araln valve O J IS iocatea upstream or tne air filter at the lowest point of the crude air pipe. Danger of engine damage! Regularly clean and check the functioning of water drain valve @ as there may be water in the crude air pipe when the drain valve is closed. This causes water to be sucked in, resulting in engine damage!

Use your hand to check the water drain valve @ for free passage Clean the valve if it is blocked

POLY-V-BELTS Push the tension~nqpullev Q downwards Remove the poly-V-belt

Example illustrated for DO836 LF engine with airconditioning system

Poly-V-belt installation is a reversal of the removal procedure.

BREATHER FOR SEMlLlFETlME OIL FlLL BREATHER FOR SEMlLlFETlME OIL FlLL The breather and the PA pipelines (PA = polyamide (plastic), 6x1 M3230) with connection system 203 (VOSS) must be renewed when changing the oil in the gearbox and/or driven axle. INSTALLATION POSITION Gearbox: -Breather

a below the air filter housing

Axle: -Breather

a above the driven axle

RENEWING Removing Mark the routing of the PA pipelines and the position of the plastic fasteners Remove all the fasteners @ Undo the mounting bolts @ on the breather (illustrated example: axle)

Unscrew the connection system union screw @ on the axle housing

BREATHER FOR SEMILIFETIME OIL FILL Cut the new PA pipeline to the desired size Only use a plastlc cutting shears (MAN no. 08.02350-9004) for cutting the pipeline to size. This is the only tool that ensures the clean and perpendicular cut that is necessary for successful assembly. It is not necessary to rework the cut, e.g. deburring on the inside and outside. Mark the required connection insert depth (19.5 mm) on the PA pipeline that is to be fitted This enables an immediate visual check for ensuring correct PA pipeline assembly.

-Do not heat the PA pipeline when routing it under any circumstances! -Keep the PA pipelines well away from any sources of heat. Route the PA pipeline so that it is free from kinks, chafing and tension. Observe the marks made whilst removing the components Remove the connection system plastic cap (assembly stopper) concerned @ from the gearbox or axle breather Press the clean PA pipeline (without paint residue or similar) into the plug connection until the stop is reached. You must overcome the resistance provided by the round rings and the toothed ring within the connection system. Briefly pull back the PA pipeline so that the holding edges running around the inside of the plug connection engage in the PA pipeline jacket Check the "insert depth" mark on the PA pipeline!

In the case of the gearbox, ensure that the PA pipeline rises (+) in addition to checking that it is free from kinks, chafing and tension!

BREATHER FOR SEMILIFETIME OIL FILL

h I

aiaelines must be fastened usina plastic fasteners. -When mounting the PA pipes, ensure that the pipe fasteners prevent the PA pipelines from turning. -The maximum distance between the fasteners is 500 to 800 mm. -Do not freely "suspend" pipe connections in PA pipelines! - PA

Fit all the plastic fasteners made durinn removal

a,observing the marks

BRAKE TECHNICAL SAFETY Rrake chaft hearinn nn wheel hrake sectinn

Lubricate the brake shaft bearings via the lubricating nipple (+) using a grease gun

ENGINE BRAKE

Gap too small: Increase torsion bar spring pretension. To do this, place an object (e.g. pliers) between the "closed" stop @ and the valve lever. Close the valve by hand and, by feeling, "overpress" the torsion bar spring against the stop.

I HEADLIGHTS ADJUSTMENT General information The vehicle and the setting instrument must be standing on a flat, level surface. Only check and adjust the headlight settings when the vehicle is unladen and the tyres have been inflated to the specified pressure. When adjusting the headlights, also refer to the headlight setting plate (co-driver side) and the "Headlight beam adjustment" table MAN no. 81.25000-8358 (also see Operator's Manual). Use the Torx 120 tool for all adjustment work.

Checking (general description) - In the case of vehicles with manual headlight

beam adjustment, the adjuster must be in position "0"(+), see Operator's Manual for setting. - In the case of vehicles with automatic headlight beam adjustment (LWR) and xenon headlights, the adjustment feature must be deactivated using MAN-Cats before adjusting the headlights (position "0").

Checkingladjustment can be performed using an optical setting instrument (see the operating instructions provided by the manufacturer concerned) or a white screen (wall) positioned 10 m away and parallel to the front of the vehicle. The following general description is based on a lefthand drive vehicle with asymmetrical driving lights. Key to diagrams: Figure I = Headlight low beam Figure II = Headlight high beam H = Height of the middle of the headlight above the ground in mm h = Height of the separating line on the screen (wall) above the ground in mm e = H minus h Setting (e) for vehicles with leaf suspension: Headlight = see adhesive label inside the right-hand door next to the type plate, indicated in % ( l % = 100 mm, 1.5% = 150 mm, 2% = 200 mm, etc.) Fog lamps = 400 mm Setting (e) for vehicles with air suspension: Headlights = 100 mm Fog lamps = 200 mm A = Headlight centre-to-centre distance

HEADLIGHTS

HEADLIGHTS For asymmetrical headlight low beam (see Figure I): Side setting The "kink" on the line where light meets dark should be on the vertical which runs through the setting cross. Height setting The point where light meets dark should touch the separating line (height h) to the left of the lower setting cross.

For headlight high beam (see Figure 11): The high beam "hotspot" (centre) should be positioned on the upper setting cross.

HEADLIGHTS Adjusting main headlights (Figure shows left main headlight) Move the headlight adjuster (see operating instructions provided by manufacturer concerned) to the "basic headlight setting" as indicated on the "Headlight beam adjustment" table (see Operator's ManualIMAN no. 81.25000-8358). - In the case of vehicles with manual headlight

beam adjustment, the adjuster must be in position "0"(+),see Operator's Manual for setting. - In the case of vehicles with automatic headlight beam adjustment (LWR) and xenon headlights, the adjustment feature must be deactivated using MAN-Cats before adjusting the headlights (position "0"). Always make sure the headlights are set to low beam before adjusting. If the low beam setting is correct, the high beam setting will be correct too.

Height setting - down Turn the upper adjusting screw anti-clockwise One revolution moves the line where light meets dark (LD line) in the headlight adjuster downwards by 0.4" and to the right by 0.3". Then perform a counter correction by turning the lower adjusting screw @ clockwise One revolution is equivalent to a counter correction of 0.3". - Adjustment by 0.4" downwards

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Height setting - up Turn the upper adjusting screw clockwise One revolution moves the line where light meets dark (LD line) in the headlight adjuster upwards by 0.4" and to the right by 0.3". Then perform a counter correction by turning the lower adjusting screw @ anti-clockwise One revolution is equivalent to a counter correction of 0.3". - Adjustment by 0.4" upwards

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Side setting - to the left (leftlright side) Turn the lower adjusting screw @ anti-clockwise/ clockwise One revolution moves the headlight to the left by 0.3". - Adjustment by 0.3" to the left Side setting - to the right (leftlright side) Turn the lower adjusting screw @ clockwiselanticlockwise One revolution moves the headlight to the right by 0.3". - Adjustment by 0.3" to the right

TYRES SPARE WHEEL MOUNTING Check that the spare wheel mounting nuts firmly seated

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Risk of injury if cable is frayed! Renew defective cables immediately Check the hoist and spare wheel mounting Check the winch cable @ Note: Do not oil or grease the winch cable, to prevent excessive dirt build-up.

TIPPER SYSTEM MEILLER THREE-WAY TIPPER SYSTEM GENERAL INFORMATION Danger of accidents! - Observe the relevant national work

safety and accident prevention regulations. - Before tipping, ensure that there are no bulk goods or freight on the loading area. - Only tip if the vehicle is standing on a flat, level and stable surface. - In the case of Caxle vehicles, the steering must be in the straight-ahead position to prevent damage to the wheel nut caps when the "Bordmatik" automatic unloading system wall is fully folded down. - Ensure that the insert pins are correctly seated when tipping! - No-one is allowed to stand in the tipper or side wall operating area. - The operator must observe the correct tipping and lowering procedure and not move away from the tipper valve actuator so that immediate action can be taken in an emergency. - Standing or working beneath a nonsupported tipper body puts lives at risk and is therefore prohibited! - Always make sure that the safety supports are attached so that they cannot slip! - Do not perform maintenance work unless the engine is stopped. - Do not increase the hydraulic system operating pressure set by the manufacturer. - Follow environmental protection guidelines! - For further details, refer to the "TIPPER OPERATION" section in the Operator's Manual.

TIPPER SYSTEM TIPPER BODY (examples illustrated) LUBRICATING THE TIPPING BOOM Oil the noise level reduction devices via the hole (2 x left, 2 x right) Oil the bearing points of the fittings Oil the bearing points of the rear wall latches Oil the bearing points of the body supports

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LUBRICATING THE AUTOMATIC SIDE WALL LATCH Lubricate the automatic side wall latches via grease nipple (+)

LUBRICATING THE "BORDMATIK"AUTOMATIC UNLOADING SYSTEM Lubricate the low-maintenance side wall bearing points regularly every 2 months using a silicone oilbased grease (commercially available). Use a fluorine/silicone oil-based high-temperature grease (commercially available) if transporting bulk goods with high temperatures (e.g. bitumen). Lubricate the bearing points of the "Bordmatik" automatic unloading system via lubricating nipple (+)

Only operate the "Bordmatik"automatic unloading system with the hydraulic pump switched on! CHECKING THE REAR WALL CATCH SETTING Automatic claw-type lock If correctly set, the automatic claw-type lock opens the steel rear wall once the tipping angle reaches approx. 5". Check that setting = 2 mm, @ = 6 mm and angle @ = 7", readjust on the linkage if necessary There must be no play between the roller and the cam (+); however, the rollers must still rotate easily Check the locking components for clearance and ease of movement

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