AC system MAN TGA, TGM

Electrical System  Air-conditioning System

Copy deadline: 03.2005

81.99198-7432 MAN Nutzfahrzeuge Aktiengesellschaft Dachauer Str. 667 80995 MÜNCHEN MÜNCHEN oder  Postfach 50 06 20 80976 MÜNCHEN MÜNCHEN

System Description T 69 3rd edition edition Systembeschreibung T 69, 3. Ausgabe Elektrische Anlage Klimaanlage - Englisch Printed Printed in Germany

System Description T 69 3rd edition

Electrical System  Air-conditioning System

81.99198-7432

PREFACE / PRINTER’S IMPRINT PREFACE

This manual is intended to provide assistance in performing repairs correctly on the vehicles and units listed here. This publication assumes that persons who use it possess the requisite technical knowledge in handling vehicles vehicles and units. Pictures Pictures and the corresponding corresponding descriptions descriptions are typical typical one-time one-time representatio representations; ns; they do not always correspond to the unit in question, but this does not necessarily mean they are incorrect. In such cases, plan and carry out the repair work in accordance with the sense of the instructions. Repair work on complex add-on units must be left to our after-sales service or the after-sales service of the manufacturer manufacturer.. These components components are mentioned mentioned specifically in the text. Importa Important nt instruc instructio tions ns relati relating ng to safety safety and accide accident nt prevent prevention ion are special specially ly highlig highlighted hted in the text text as follow follows. s. CAUTION Type and source of danger 

• Refers to working and operating procedures which must be followed exactly in order to avoid exposing people to risk WARNING Type and source of danger 

• Refers to working and operating procedures which must be followed in order to avoid material damage or destruction. destruction. Note

 An explanatory note which is useful for understanding the working or operating procedure to be performed. Comply with general safety regulations when performing any repair work. Best wishes from MAN Nutzfahrzeuge Aktiengesellschaft Munich Plant

PRINTER'S IMPRINT

We reserve the right to make modifications cations in the course course of further development. 2005 MAN Nutzfahrzeuge Nutzfahrzeuge Aktiengesellsc Aktiengesellschaft haft

Reprinting, copying or translation, even of extracts, is not allowed without the written approval of MAN Nutzfahrzeuge AG.  All rights under the copyright law are a re strictly reserved by MAN Nutzfahrzeuge AG. If any changes are made without the written approval of MAN Nutzfahrzeuge AG then MAN Nutzfahrzeuge  AG shall not be liable for any warranty or guarantee claims arising from damage and defects attributable to the unauthorised modification. Furthermore, MAN Nutzfahrzeuge AG shall not be liable for any damage resulting resulting from the unapproved modification. Redaktion: Redaktion: VSAID-Steyr, VSAID-Steyr, HA, 03.2005 Satz: VSAID-Steyr  Druck: MAN-Werksdruckerei

II

T 69

TABLE OF CONTEN CONTENTS TS Content

Chapter/Page

I n de x

V

Abbreviations

V II

Introduction

................................................................................................ ...................................... .... 1 - 1 Safety instructions .............................................................. .............................................................................................. ......................................... ......... 1 - 6 Model overview .............................................................. ........................................................................ ........... 1 - 8 Explanatory notes to the wiring diagrams ............................................................. Device description

System description ............................................................. ............................................................................................... ..................................... ... 2 - 11 General information .............................................................. ............................................................................................. ............................... 2 - 11  Air-conditioning system ................................................................ ......................................................................................... ......................... 2 - 11 Functional description ............................................................... .............................................................................................. ............................... 2 - 13 Description of components ............................................................... ........................................................................................ ......................... 2 - 23 Control element, cab heating with air-conditioning system (A474) ..................................... ..................................... 2 - 23 High/low-pressure switch on refrigerant tank (B203) ..................................................... ..................................................... 2 - 24 Compressor with magnetic coupling (Y114) ............................................................... ................................................................. 2 - 25 Solenoid valve, air-conditioning system at front end (Y117) ............................................. ............................................. 2 - 26 Condenser  ................................................................ ................................................................................................. ........................................ ....... 2 - 27 Temperature sensor, internal air-conditioning (B393) ..................................................... ..................................................... 2 - 28 .................................................................................. ................ 2 - 29 External temperature sensor  .................................................................. ............................................................................................... ............................... 2 - 30 Evaporator sensor  ................................................................ .............................................. .................................. ............ 2 - 31 Heat exchanger sensor (blow-out air temperature sensor) ................................................................................................. .............................................. ............ 2 - 32 Diagnosis ............................................................... ............................................................................................. ............................... 2 - 32 General information .............................................................. SPN list (fault codes) and fault code description, control element ...................................... 2 - 39 Test step list for air-conditioning system .....................................................................2 - 43 Additional Additional wiring diagrams

Overviews ............................................................... ................................................................................................. .............................................. ............ 3 - 51 Brief overview of the air-conditioning system ...............................................................3 - 52 wiring diagram No. 81.99192.1380 .............................................................. .............................................................................. ................ 3 - 54  Air-conditioning system wiring diagram ............................................... sheet 1 of 2 ....... 3 - 54  Air-conditioning system wiring diagram ............................................... sheet 2 of 2 ....... 3 - 56

T 69

I II

INDEX Catchword

Page

A

 Air conditioning, system....................................................................... system....................................................................... ..................................................... 2 -  11 B

Brief overview of the air-conditioning system ...........................................................................................3 -  53 C

Compressor with magnetic coupling (Y114) Components ........................................................................................................................................2 Function...............................................................................................................................................2 Function ...............................................................................................................................................2 Condenser  Components ........................................................................................................................................2 Function...............................................................................................................................................2 Function ...............................................................................................................................................2 Connection valves ....................................................................................................................................2 Control element, cab heating with air-conditioning system (A474) Components ........................................................................................................................................2 Connector pin assignment...................................................................................................................2 assignment ...................................................................................................................2

-  25 -  17 -  27 -  20 -  20 -  23 -  14

D

Description of the refrigerant circuit..........................................................................................................2 circuit ..........................................................................................................2 -  13 Diagnosis socket (X200)...........................................................................................................................2 (X200)...........................................................................................................................2 -  34 Diagnosis socket HD-OBD (X200)  (X200)   ...........................................................................................................2 -  34 E

Evaporator ................................................................................................................................................2 Evaporator ................................................................................................................................................2 -  20 Evaporator sensor  Components ........................................................................................................................................2 -  30 Function...............................................................................................................................................2 Function ...............................................................................................................................................2 -  15 Explanatory notes to the wiring diagrams...................................................................................................1 diagrams. ..................................................................................................1 -  8 External temperature sensor  Components ........................................................................................................................................2 -  29 Function...............................................................................................................................................2 Function ...............................................................................................................................................2 -  15 F

Filling air-conditioning systems.................................................................................................................2 systems .................................................................................................................2 -  22 Fluid tank ..................................................................................................................................................2 -  18 Function diagram of the refrigerant circuit ................................................................................................2 -  13 G

General information, diagnosis.................................................................................................................2 diagnosis .................................................................................................................2 -  32 General information, system................................................................ system................................................................ ..................................................... 2 -  11 H

Heat exchanger sensor (blow-out air temperature temperature sensor) Components ........................................................................................................................................2 Function...............................................................................................................................................2 Function ...............................................................................................................................................2 Heater element bypass  fl ap......................................................................................................................2 ap ......................................................................................................................2 High/low-pressure switch on refrigerant tank (B203) Components ........................................................................................................................................2 Function...............................................................................................................................................2 Function ...............................................................................................................................................2

-  31 -  15 -  17 -  24 -  19

I

Installation positions for diagnosis socket ................................................................................................2 socket  ................................................................................................2 -  36 Installation positions for location identi fiers ................................................................................................1 -  9 M

Main functions, diagnosis .........................................................................................................................2 -  37 Model overview...........................................................................................................................................1 overview...........................................................................................................................................1 -  6 R

Refrigerant circuit and its components .....................................................................................................2 -  12 T 69

V

INDEX

Refrigerant oil  fi ll volume ..........................................................................................................................2 -  22 Refrigerant R 134a ...................................................................................................................................2 -  21 S

Selecting between air-conditioning system modes AC or REHEAT .........................................................2 - 16 -  16 Solenoid valve, air-conditioning system at front end (Y117).....................................................................2 (Y117).....................................................................2 - 26 -  26 SPN list (fault codes) and fault code description, control element ...........................................................2 element  ...........................................................2 - 39 -  39 System structure, K-lines..........................................................................................................................2 K-lines..........................................................................................................................2 -  32 T

Temperature sensor, internal air-conditioning (B393) Components ........................................................................................................................................2 Function...............................................................................................................................................2 Function ...............................................................................................................................................2 Test description.........................................................................................................................................2 description.........................................................................................................................................2 Test step list..............................................................................................................................................2 list ..............................................................................................................................................2 Test step list for air-conditioning system ...................................................................................................2 Thermostatic expansion valve ..................................................................................................................2 Troubleshooting program  program  .........................................................................................................................2

-  28 -  16 -  43 -  44 -  43 -  19 -  38

W

Wiring diagram, air-conditioning system...................................................................................................3 system...................................................................................................3 -  54

VI

T 69

LIST OF ABBREVIATIONS Abbreviations A

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

Acceleration General certification Antilock Braking System Anti-skid system Air Conditioning Adaptive Cruise Control Acknowledge Analogue-Digital Converter  European agreement agre ement for cross-border transport of dangerous goods by road (French title: Accord européen relatif au transport international des marchandises Dangereuses par Route) Automatic road speed limiter  Analogue Ground Exhaust gas recirculation Trailer coupling Trailer brake valve Automatic load balancing Antenna mast system Trailer/semitrailer  Automatic gearbox Trailer socket Trailer control module Anti-Spin Regulation (traction control) Trailer control valve Automatic Temperature Control Automatic Transmission Fluid Statutory exhaust emission test Exhaust valve Automatic gear preselection

B

BA BBA BB A BBV BB V BKR BK R BUGH BUGH BV BVA BV A BVS BVV BV V BW BWG BWG BZ

Operator’s r’s Manual Servi rvice brake syste stem Servi rvice brake ake valve Brak Brake e powe ower regu regula lato tor  r  Front ront heat heater  er  Backup valve Brak Brake e wear ear ind indicat icator  or  Brake wear sensor  Brak Brake e wear wear sen sensor sor supp supplly German Army Brak Brake e power ower sens sensor  or  Brake cylinder  

C

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

Control Controller ler Area Area Networ Networkk (data (data bus system system with with serial serial bit transmis transmissio sion) n) CANCAN-hig high h data data line line CANCAN-lo low w data data line line Comput Computer-a er-assi ssiste sted d testin testing g and diagnos diagnostic tic system system Central tral Brak Brake e Unit Crui Cruise se Contro Controll Vehic ehicle le Speed Speed Comple Completel telyy Knocked Knocked Down Down (compl (completel etelyy dismant dismantled led vehicle vehicle)) Compr ompres esssed Natu Natura rall Gas Gas Centr entral al Proc Proces essi sing ng Unit Unit Conti Continuo nuous usly ly Rege Regener nerat atin ing g Trap Trap (exha (exhaus ustt muf  muf fler, two-way catalytic converter, diesel particulate filter) Cycl Cyclic ic Redu Redund ndan ancy cy Chec Checkk Comfort Shift

T 69

V II

LIST OF ABBREVIATIONS D

DAHL DAHL DBR DBR DECK DECKE E DF DFÜ DIA DIA DIAK DIAK DIAL DIAL DIAR DIAR DIN DKE DKE DKH DKL DKR DKV DLB DLB DM DNR DPF DPF DRM DRM DS DSV DSV DTCO DTCO DV DWA DWA DZG DZM

Roof oof venti entila lato tor  r  Auxi Auxilliary iary brak brake e rela relayy Cove Coverr (for (for doors doors)) Speed sensor   Data transmission Diag Diagno nosi siss and and info inform rmat atio ion n disp displa layy Diag Diagno nosi sis, s, K-li K-line ne (dat (data a line line)) Diagn Diagnosi osis, s, L-lin L-line e (int (interr errog ogat atio ion n line line)) Diagn Diagnos osis is,, furth further er interr interrog ogat ation ion Germ German an ind industr ustria iall stan standa dard rd Thro Thrott ttle le valv valve e incr increas ease e (ASR (ASR cont contro rol) l) Roof duct heat eating Roof  flaps Thrott Throttle le valve valve reduct reduction ion (reducti (reduction on reques requestt from ASR to EDC/EM EDC/EMS) S) Thro Thrott ttle le valv valve e speci pecification (load sensor signal from pedal value sensor, EDC/EMS) Comp Compre ress ssed ed air air brak brake e syst system em Diagnostic Message Drive Drive Neutral Neutral Reverse Reverse (select (selector or lever lever switch switch for automati automatic) c) Dies Diesel el Part Partic icul ulat ate e Filt Filter  er  Pres Pressu sure re cont contro roll modu module le Pressure sensor   Pres Pressu sure re contr ontrol ol valv valve e Digi Digita tall tach tachog ogra raph ph Throttle valve Anti Anti-t -the heft ft warn warnin ing g syst system em Speed sensor  Rev counter 

E

EBS EBS ECAM ECAS ECAS ECE ECE ECU ECU EDC EDC EDM EDR EDR EEC EE C EEPROM EFR EFS EF S EHAB ELAB ELAB ELF EMS EMV EOL EOL EP ER ESAC ESA C ESP ES P ESR ES R EST ES T EV EVB

Elec Electr tron onic ic Brak Brakin ing g Syst System em Electr Electroni onical cally ly Contro Controlle lled d Air Managem Management ent Electro Electronic nicall allyy Controll Controlled ed Air Suspens Suspension ion Emer Em erge genc ncyy shut shut-o -off ff to ECE ECE 36 Elec Electr tron onic ic Cont Contro roll Unit Unit Elec Electr tron onic ic Dies Diesel el Cont Contro roll Electr Electroni onicc Diesel Diesel consum consumpti ption on Measurin Measuring g system system Top spee speed d gove govern rnor  or  Elec Electr tron onic ic engi engine ne cont contro rollller  er  Electrically Electrically erasable and programmable programmable read-only memory Elec Electro troni nicc shoc shockk absorb absorber er cont control rol (ESAC (ESAC)) Elec Electr triic drive river' r'ss seat seat Electr Electro-h o-hydra ydrauli ulicc shut-of shut-offf device device Elec Electr tric ical al shutshut-of offf device device Elec Electro troni nica callllyy contr control olle led d air air susp suspens ensio ion n Elec Electro tronic nic thro throttl ttle e cont control rol (ETC) (ETC) Elec Electro tromag magne neti ticc compa compati tibi bilility ty (EMC) (EMC) EndEnd-of of-l -lin ine e (pro (progr gram ammi ming ng)) Injection pump Eng Engine ine reta retard rder er (eng (engiine bra brake) ke) Elec Electr tron onic ic Shock Shock Absorb Absorber er Contr Control ol Elec Electr tron onic ic Stab Stabililit ityy Prog Progra ram m Elec Electr triic sun-b un-blilind nd Elec Electr tro onic nic cont contrrol unit unit Intake valve Exhaust Valve Brake rake

F

FAP FAQ FBA FB A VIII

Driver's area Freq Freque uent ntly ly Aske Asked d Ques Questi tion onss Parking ing brak rake system T 69

LIST OF ABBREVIATIONS

FDR FDR FDF FFR FFR FGB FGB FGR FGR F HS FIN FM FMI FMI FMS FMR FMR FOC FSCH FS CH FSG FS G FSH FS H FTW FTW FUNK FUNK FZA FZA FZNR FZNR

Dyna Dynami micc hand handliling ng cont contro roll Vehicle data file Vehic ehicle le mana manage geme ment nt comp comput uter  er  Road speed limi limitter  Road spee speed d gover overno nor  r  Cab Vehicle identification number (17 digits) digits) Vehicle management Failu ailure re mode ident entification Fleet Fleet Manage Management ment Standard Standard (globa (globall telemati telematics cs standar standard) d) Vehic ehicle le/e /eng ngin ine e mana manage geme ment nt Front Front Omnibus Omnibus Chassi Chassiss (bus/c (bus/coac oach h chassi chassiss with with front-m front-mount ounted ed engine engine)) Wind Windsc scre reen en heat heater  er  Grou Ground nd rein reinfo forc rcem emen entt syst system em Wind Window ow/m /mir irro rorr heat heatin ing g Drive river' r'ss part partiitio tion Radio Radio comm communi unica cati tion on unit unit Destination system Vehic ehicle le numbe numberr (7 digits digits))

G

GDK GDK GE N GE T GGVS GND GP GS GV

Contr Control olle led d dies diesel el catal catalyt ytic ic conv conver erter  ter  Alternator  Gearbox European European agreement agreement for cross-border cross-border transport transport of dangerous dangerous goods by road (French abbreviation: abbreviation:  ADR) Ground Gear Gearbo boxx plan planet etar aryy gear gear group group (rang (rangee-ch chang ange e box) box) Gearbox control Gear Gearbo boxx spli splitt tter er gear gear grou group p (spl (split itte terr box) box)

H

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

Rear axle Auxi Auxilliary iary brake rake syst system em Maxi Maximu mum m road road spee speed d limi limite ter  r  Hydra ydraul uliic gear gearsh shif iftt Hydros drosta tati ticc fan fan Rear Rear Omnibu Omnibuss Chassis Chassis (bus/co (bus/coach ach chassis chassis with with rear-mo rear-mount unted ed engine) engine) Highside swit witch Main switch tch pan panel Main inspection Hertz ertz (num (numbe berr of cycl ycles per seco second nd)) Bus Bus stop top indi indica cattor syst system em Auxi Auxilliary iary spee speed d senso ensor  r 

I

IBEL IBEL IBIS IBIS IC ID IMR INA INA IR IRM ISO IWZ

Inter nterio iorr liligh ghti ting ng Integ Integra rate ted d on-bo on-board ard infor informa mati tion on syst system em Integrated Circuit Identification Integ Integra rate ted d mech mechani anica call relay relay (star (starte terr cont control rol)) Info Inform rmat atio ion n indi indica cato torr (e.g (e.g.. chec checkk lamp lamp)) Individ vidual ual control trol (AB ABS) S) Modified individual control (ABS) Inter Interna nati tion onal al Standa Standards rds Organ Organis isati ation on Incr Increme ement ntal al angle angle/ti /time me meas measur uring ing syste system m

K

KBZ KBZ KFH KITAS KITAS KLI KLI

Comb Combin inat atio ion n brak brake e cyli cylind nder  er  Fuel filter heater  Kienzl Kienzle e intelli intelligen gentt tachogr tachograph aph sensor  sensor  Air Air-con -condi diti tion oniing sys system tem T 69

IX

LIST OF ABBREVIATIONS

KNEE KNEEL L KSM KSW KS W KWP

Knee Kneeliling ng Custome tomerr-spe -speccified control module (control unit for external data exchange) Cust Custom omer er's 's spec specia iall requ reques estt Key Word Word Protocol Protocol (protoc (protocol ol for MAN-ca MAN-cats ts diagno diagnosis sis))

L

LB H LCD LCD LDA LDA LDF LDF LDS LDS LED LF LGS LL LLA LLR LNA LNA LNG LOE LOE LP G LWR LSVA LSVA

Air reservoir  Liqu iquid cryst rystal al disp displa layy Mani Manifol fold-p d-pre ress ssur ure e comp compens ensat ator or (boos (boostt cont control rol)) Char harge pre pressur ssure e sen sensor  sor  Air Air spri spring ng/d /dam ampe perr syst system em Ligh ight emit mitting diode ode Air suspension Lane Guard System Idling speed Idling spee peed increase ease Idling spee peed contr ntrol Stee Steeri ring ng trai traililing ng axle axle Liquefied Natural Gas Stee Steeri ring ng oil oil moni monito tor  r  Liquefied Petroleum Gas Head Headliligh ghtt beam beam regu regula lato tor  r  Dista Distanc nce-b e-bas ased ed heav heavyy vehi vehicl cle e toll toll

M

M-TC M-TCO O Modul Modular ar EU tacho tachogr grap aph h MAB Soleno Solenoid id valve valve shut-o shut-off ff (engin (engine e shutshut-off off by high high-pre -pressu ssure re solen solenoid oid valve valve in in inject injection ion pump) pump) MAN- cats MAN computer-assisted computer-assisted testing and diagnostic diagnostic system MAR Soleno Solenoid id valve valve shut-of shut-offf relay relay (redunda (redundant nt engine engine shut-of shut-offf relay) relay) MDB Engi ngine speed rang ange MES ME S Qua Quantit ntityy pos positio itione ner  r  ML Midline MMI MMI Man-m an-mac achi hine ne inte interf rfac ace e MOTB MOTB Eng Engine ine brak brake e MP Moto Motorr powe powerr box box (cab (cable le duct duct on engi engine ne bloc block) k) MR Engine governor - ASR MSG MS G Engi Engine ne cont contro roll unit unit (EDC (EDC)) MV Solenoid valve MZ Diaphragm cylinder  N

n NA NBF NBF NES NES NFZ NLA NSL NSW

Engine speed Power take-off   Needl eedle e move moveme ment nt senso ensor  r  New New Elec Electr tron onic ic Stru Struct ctur ure e Comm Commer erci cial al vehi vehiccles les Trailing axle Rear fog lamp Fog lamp

O

OBDU OBDU OC OEAB OEAB OENF OENF

Onboard Onboard Diagno Diagnosti sticc Unit Unit (sub (subsys system tem of cent central ral on-boar on-board d comput computer) er) Occur Occurre renc nce e coun countt (fre (freque quenc ncyy coun counte terr of a faul fault) t) Oil Oil sepa separa rato tor  r  Oil Oil repl replen enis ishe her  r 

P

p PBM PLM PLM PSG PS G PTO X

Pressure Pulse Pulse Bread Breadth th Modul Modulat atio ion n (als (also o see see PWM) PWM) Prog Progra ramm mmab able le Logi Logicc Modu Module le Pum Pump cont contro roll unit unit (EDC (EDC)) Power take-off  T 69

LIST OF ABBREVIATIONS

PWM

Pulse Pulse Width Width Modu Modula lati tion on (als (also o see see PBM PBM))

R

RA RAH RAM RAM RAS RAS RAS-EC RDRA RDRA RDS RDS RE T RKL RKL RLV RME RME ROM ROM

Repair Manual Interio eriorr heat eating Rando andom m Acce Access ss Memo Memory ry Rear Axl Axle Ste Steering Rear Axle Steering Steering with with Electroni Electronicc Control Control Tyre yre press pressur ure e cont control rol syst system em Radio Data ata System Retarder   Pri Priorit orityy vehi vehicl cle e light ight Relay valve Rape Rape seed seed oil oil meth methyl yl este esterr (biodi (biodies esel el)) Read Only nly Memor mory

S

SA SAE SA E SAMT SB sec SER SE R SG SH SKD SK D SL SML SM L SPN SP N STA ST A SWR SWR

Special equipment Soci Societ etyy of Auto Automo moti tive ve Engi Engine neer erss Semi-a Semi-auto utomati maticc mechani mechanical cal transm transmiss ission ion Service outlet Second Stan Standa dard rd/s /ser erie iess prod produc ucti tion on Control unit Selec lect-high control rol (AB (ABS) Semi Kno Knocke cked Down Select lect--low contr ntrol (ABS (ABS)) Side mark marker er light ghts Susp Suspec ectt Para Parame mete terr Num Number  ber  Engine start/stop Head Headliligh ghtt clea cleani ning ng syst system em

T

t TBM TB M TC TCM TCM TCO TKU TK U TMC TPM TP M TRS TSC TS C TSU TUE TUER

Time On-b On-boa oard rd tele telema mati tics cs modu module le Traction Control Trai railer ler Cont Contro roll Modu Module le Tachograph Techn echnic ical al cust custom omer er docu docume ment nt Traffi  c Message Channel Tyre yre Pres Pressu sure re Modu Modulle Techni echnica call road road trans transpo port rt dire direct ctiv ives es Torqu orque e Spee Speed d Contr ontrol ol Tachogra achograph ph Simulat Simulating ing Unit Unit (vehicl (vehicles es withou withoutt MTCO/D MTCO/DTCO TCO)) Door control rol

U

UBat UDF UDS

Battery voltage Conversion file Crash recorder 

V

v VA VDF VG VLA

Road speed Front axle Vehicle data file Transfer case Leading axle

W

WA WAB WaPu aPu

Maintenance Manual Wate ater sepa eparat rator  Water ater pump pump Inta Intard rder  er  T 69

XI

LIST OF ABBREVIATIONS

WL E WR WS WSK

Swap-body unit Warning relay Position sensor  Torque orque conv convert erter er and clut clutch ch unit unit

Z

z ZBR ZB R ZBRO ZBRO ZDR ZDR ZE ZR ZS ZUSH ZUSH ZWS   λ µ µC

XII

Braking rate/deceleration Cent Centra rall on-b on-boa oard rd comp comput uter  er  Cent Central ral on-bo on-board ard bus comp compute uter  r  Inte Interm rmed edia iate te spee speed d gove govern rnor or (ISG (ISG)) Centr ntral electrical system Central computer  Central lubrication Auxi Auxililiar aryy heat heater  er  Time-ba ime-base sed d main mainten tenan ance ce syst system em Slip Coefficient   of friction Micr Microc ocon ontr trol olle lerr (mic (micro ropr proc oces esso sor) r)

T 69

INTRODUCTION

INTRODUCTION SAFETY INSTRUCTIONS General information information

Workin Working g with with trucks, trucks, buses buses and the accomp accompany anying ing servic service e product productss should should not pose any proble problems ms if operato operators, rs, maintenance personnel and repair staff receive suitable training. The following sections include   summaries  of important important regulations regulations listed according according to major topics. The intention is to provide the knowledge needed to avoid accidents which could lead to injury, damage and environmental environmental pollution. pollution.   The They y repre represe sent nt only only a small small excerp excerptt from from the the wide wide range range of accid acciden entt preve preventi ntion on regulations and cannot replace these.  It goes without saying that all other safety regulations must be followed and that the corresponding action must be taken..  Additional danger warnings appear in the manuals whenever potential risks are a re involved.  Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality, obtain immediate medical assistance from a doctor. This is particularly important if the accident involves skin contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes, etc. 1. Regulations for preventing accidents leading to injury to personnel  –  Secure units during their removal.  –  Support the frame when working on the pneumatic or spring suspension system.  –  Keep units, ladders, stairs, steps and the surrounding area free from oil and grease.

 Accidents caused by slipping s lipping can ca n have h ave very serious consequences. Only authori authorised sed techni technical cal personne personnell are entitled entitled to perform perform inspect inspection, ion, adjustment and repair work

Working on the brake system  –  Perform visual, function and effectiveness checks on the brake system after carrying

out any work on it whatsoever whatsoever.. These checks must be made in accordance with the safety inspection (SP).  –  Check the function of ABS/ASR and EBS systems using a suitable test system (e.g. MAN-cats).  –  Collect hydraulic oil and brake fluid as it drains out.  –  Hydraulic oil/brake fluid is poisonous! Do not allow brake fluid to come into contact with food or open wounds.  –  Treat hydraulic oil/brake fluid as hazardous waste! Comply with the safety regulations for preventing environmental pollution.

T 69

1-1

INTRODUCTION

Operating the engine authorised personnel personnel are permitted to start and operate an engine.  –  Only authorised  –  Do not approach moving parts of a running engine too closely.

Do not wear baggy clothing and tie up or cover long hair. Ensure adequate ventilation ventilation if you are working in enclosed spaces.  –  Do not touch units with your bare hands when they are at operating temperature. Danger of burns!  Always wear protective gloves when changing oil (in units at operating temperature) tem perature) in particular.  –  Do not open the coolant circuit unless the engine is cool. Suspended loads  No-one is allowed to stand under a unit suspended suspended from a crane hook. - Keep all  –  No-one

lifting tackle in good condition -

Working on high-pressure lines  –  Do not attempt to tighten or loosen pipe lines and hoses when they are under 

pressure (e.g. lubrication circuit, coolant circuit and hydraulic oil circuit). Fluid spraying out represents an injury hazard! checking the injector nozzles. nozzles. Do  –  Do not hold your hands under the jet of fuel when checking not inhale fuel vapours. Working on the vehicle electrical system  –  Always disconnect the batteries before working on the electrical system.

Disconnect the earth cable first and connect it last when reconnecting.  –  Measure voltage only using a suitable measurement device.

The input resistance of the measurement device must be at least 10 M Ω.  Tow-startt the vehicle vehicle only with the batteries connected (minimum (minimum charge 40%)! Do  –  Tow-star not use a boost-charger boost-charger to jump-start jump-start the vehicle! Always disconnect disconnect the positive positive and negative leads before boost-charging batteries.  –  Disconnect the batteries and recharge them every 4 weeks if the vehicle is not in use.  –  The ignition must be switched off before the wiring harness plugs of the electronic control units are disconnected or connected up. Important! Battery gases gases are explosive!  Oxyhydrogen gas may form in enclosed enclosed battery boxes. Take particular particular care after   –  Oxyhydrogen

long journeys and after charging charging the batteries batteries with a battery charger. charger.  –  When the batteries are disconnected this gas may be ignited by sparks produced by other continuously continuously operating operating consumers, consumers, the tachograph etc. that cannot be shut down. Blow compressed compressed air through the battery battery box before disconnectin disconnecting g the batteries! Avoid d shor shortt circ circui uits ts caus caused ed by pola polarit rityy reve revers rsal al or by plac placin ing g metal metal obje object ctss (span (spanne ners rs,,  – Avoi mole grips, etc.) on the battery terminals. Caution! Battery acid is poisonous and corrosive!  –  Wear appropriate protective clothing (gloves) when handling batteries.

Do not tilt batteries, acid may leak out.

1-2

T 69

INTRODUCTION

Electric welding welding  –  Connect up the "ANTIZAP SERVICE MONITOR" protective device (MAN item

number 80.78010.0002 80.78010.0002)) in accordance accordance with the instructions instructions supplied supplied with with the device. device.  –  If this device is not available, disconnect the batteries and connect the positive cable to the negative cable in order to make a conductive connection.  –  Always earth the welding equipment as close as possible to the welding area. Do not lay the cables to the welding equipment in parallel to electrical cables in the vehicle. chassis is not intend intended ed for use as an earth return! return! If attachme attachments nts are to be  –  The chassis fitted to the vehicle (e.g. a taillift), additional earth (ground) lines with an adequate cross-section must be  fi tted as well. Otherwise the earth connection may be created along wire cables, cables, wiring harnesses, gearbox shafts, shafts, gears etc. Severe damage damage could result. Painting  –  If paint spraying is to be carried out, do not expose the electronic components to

high temperatures (max. 95 °C) for more than brief periods; a time of up to 2 hours is permissible at a maximum of 85 °C. Disconnect the batteries. Working on plastic tubes - Danger of damage and  fi re!  –  The warning sign opposite is attached to the inside of the diesel fuel or heating oil

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

Working with the cab tilted  –  Keep the tilting area in front of the cab clear.  –  Keep out of the area between the cab and the chassis during the tilting process. This

is a danger area!  –  Always tilt the cab past the tilting point to its final position Working on the air-conditioning system  –  Refrigerants and refrigerant vapours represent a health hazard. Avoid direct contact

and protect your hands and eyes at all times.  –  Do not drain gaseous refrigerants in enclosed areas.  –  Do not mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant. 2. Notes on preventing damage and premature wear on units  –  Only subject units to the load which they have been designed to cope with in accordance with their 

designated use. Do not overload them.  –  If a fault occurs during operation, determine its cause immediately and correct the problem before the fault can get any worse.  –  Clean the units thoroughly before repairs. Ensure that no dirt, sand or foreign objects can get into the units whilst whilst carrying carrying out repairs. repairs.  Only use genuine spare parts. Fitting "equivalen "equivalentt parts" made by other companies can lead to severe  –  Only damage, damage, and the workshop that did the work will be responsible responsible for it. See the section entitled entitled "Limited liability liability for accessories accessories and parts".  –  Never run a unit dry, in other words always make sure that it has been filled with oil before running it.  –  Never run engines without coolant.  –  Apply a suitable information sign to units that are not ready to be operated.

T 69

1-3

INTRODUCTION  –  Only use fuels and lubricants (engine oil and transmission fluid as well as antifreeze and anti-corrosion

protection) that have been approved by MAN. Keep your workplace clean.  – Comply with the speci fied maintenance intervals. not fill engine/ engine/gear gear oil above above the maximum maximum level level mark. mark. Do not exceed exceed the maximum maximum permit permitted ted operat operation ional al  –  Do not tilt.  –  Severe damage to the unit could result from failure to follow these regulations. 3. Limited liability liability for accessories accessories and parts

In your own interests, you are recommended to use only accessories expressly approved by MAN and genuine genuine MAN parts. parts. The reliab reliabili ility ty,, safety safety and suitab suitabili ility ty of these these parts parts and accesso accessorie riess have have been been determi determined ned specifically for MAN vehicles. Despite Despite constant market observation, observation, we cannot judge the aspects of other  prod produc ucts ts,, nor nor can can we acce accept pt respo respons nsib ibililit ityy for for them them – even even if they they have have been been of ficially cially approve approved d by the German German TÜV technical inspection authorities or some other of ficial body. Attachments and special bodies

Comply with the safety instructions and regulations issued by the body builder in question if attachments or  special bodies have been  fi tted. Always follow the instructions in the appropriate MAN Guide to Fitting Bodies (www.manted.de). Taking out of operation and storing

The special measures described in MAN Works Standard M 3069 Part 3 apply if buses or trucks are to be withdrawn from service or stored for a period longer than 3 months. 4. Handling brake pads and similar components components  –   Harmful dust may be released when brake pads or linings are reworked – in particular when they are

skimmed or ground – and when wheel brakes are blown out.  –   Please take the necessary precautionary measures and observe the following safety advice to avoid possible damage to your health:  –  If possible, carry out the work in question in the open or in an area equipped with an ef ficient ventilation system.  –  If possible, use hand-operated or slow-running tools, equipped with a dust-collector if required.  –  Fast-running tools should always be fitted with such devices.  –  If possible, wet the workpiece prior to cutting or drilling.  –  Dispose of brake pads or linings as hazardous waste in an environmentally sound manner. 5. Regulations Regulations for avoiding avoiding injury and environmental contamination contamination Coolant

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

Do not pour cleaning fluids and rinsing water down the drain if this practice is restricted by speci fic local regulations. However, the cleaning  fl uid and rinsing water must in all cases have been passed through an oil trap with a sludge trap. Cleaning the filter insert

When blowing compressed air through the filter insert, make sure the filter dust is collected by a vacuum or is blown into a dust collection collection bag. Otherwise, Otherwise, use a respiratory respiratory protection protection mask. Wear suitable suitable rubber  gloves or use a skin barrier cream when washing out the insert, because cleaning agents have aggressive grease-dissolving characteristics. Engine/gear oil, filter cartridges, inserts and box-type  fi lters, desiccant cartridges

Only Only disp dispos ose e of used used oil oil at an appro approve ved d coll collec ecti tion on poin pointt or depo depot. t. It is extre extreme mely ly impo importa rtant nt that that oil oil is is not pour poured ed down the drain or onto the ground since it can pollute drinking drinking water! Filter inserts, inserts, cartridges and box-type hazardous waste materials materials filters (oil and fuel filters, desiccant cartridges for the air dryer) are classi fied as hazardous and must be disposed of properly. Please follow the instructions issued by the relevant local authority. Used engine/gear oil

Lengthy Lengthy or repeated repeated skin contact with any type of engine/gear oil removes removes grease from the skin. This can caus cause e dry dry skin skin,, irrit irritat atio ion n or skin skin inflammati ammation. on. In additi addition on to these these hazard hazards, s, used used engine engine oil contai contains ns dangerou dangerouss materials which have been shown to have a carcinogenic effect in animal skin tests.

1-4

T 69

INTRODUCTION 6. Health protection protection precautions precautions  –  Avoid lengthy, excessive or repeated skin contact with used oils.  –  Protect your skin using a suitable skin protection agent or protective gloves.  –  Clean areas of skin which have come into contact with engine oil.  –  Wash the areas thoroughly with soap and water. increase the cleaning cleaning effectiveness. effectiveness.  –  Use a nail brush to increase  –  Special cleaning agents make it easier to clean dirty hands.  –  Do not use petrol, diesel oil, gas oil, thinners or solvents.  –  Apply a greasy skin cream after cleaning your skin.  –  Change out of clothing or shoes which have become soaked with oil.  –  Never put oil-soaked rags into your clothing pockets. Take care to dispose of used engine/gear oil properly. - Oils can damage groundwater quality -

Therefore, never pour used oil onto the ground, into water or down the drains or sewers. Failure to comply with these instructions can lead to prosecution. Collec Collectt and dispose dispose of used oil carefully carefully.. Contact Contact the point point of sale, sale, suppli supplier er or your your local local authori authority ty for  information about collection depots. Extract from "Information on dealing with used engine oil" The Mineral Oil Traders’ Association (MINERALÖLWIRTSCHAFTSVERBAND E.V.) Steindamm 71, D-20099 Hamburg

T 69

1-5

INTRODUCTION MODEL OVERVIEW OVERVIEW

The System Description T 69 (3rd) Air-conditioning System - 03.2005 edition, can be used for the following vehicles. Trucknology Trucknology Generation A (H01-H99) (H01-H99) Model Model designation

Model Model designation

HW2

TGA 33.D20 33.D20 6X4 BB-WW BB-WW

H45

TGA 24.D20 6X2-2 LL-U

H01

TGA 18.D28 4X2 BL-TS

H46

TGA 41.D28 8X4 BB-WW

H02

TGA 18.D28 4X2 BB

H47

TGA 26/33.D20 26/33.D20 6X6H 6X6H BB

H03

TGA 18.D20 4X2 BB

H48

TGA 32.D28 32.D28 8X4 8X4 BB

H05

TGA 18.D28 4X2 BL

H49

TGA 32.D20 32.D20 8X4 8X4 BB

H06

TGA 18.D20 4X2 BL

H50

TGA 35.D20 8X6H BB

H07

ECT 18.ISM 4X2 BL

H51

TGA 18.D28 18.D28 4X4 4X4 BB

H08

TGA 18.D20 4X2 BL-TS

H52

TGA 18.D20 18.D20 4X4 4X4 BB

H09

TGA 18.D28 4X2 LL

H54

TGA 33.D28 6X6 BB-WW

H10

TGA 18.D20 4X2 LL

H55

TGA 26/33.D28 26/33.D28 6X6 BB

H12

TGA 18.D28 4X2 LLS-U

H56

TGA 26/33.D20 26/33.D20 6X6 BB

H13

TGA 18.D20 4X2 LLS-U

H57

TGA 40.D28 6X6 BB-WW

H14

TGA 18.D28 4X2 LL-U

H58

TGA 40.D20 6X6 BB-WW

H15

TGA 18.D20 4X2 LL-U

H60

TGA 19.D28 4X2 BB-WW-SKD

H16

TGA 26.D08 6X2-4 BL

H61

TGA 18.D28 18.D28 4X2 4X2 BL-WW-SKD BL-WW-SKD

H17

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

H62

TGA 33.D28 6X4 BB-WW-SKD

H18

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

H63

TGA 26.D28 26.D28 6X4 6X4 BL-WW-SKD BL-WW-SKD

H19

TGA 26.D08 6X2-4 LL

H68

TGA 40.D28 6X4 BB-WW-CK BB-WW-CKD D

H20

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

H69

TGA 39.D20 8X2-4 BL

H21

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

H70

TGA 18.D28 4X4 BL

H22

TGA 18.D20 4X4H BL

H71

TGA 28.D28 6X2-4 BL/LL

H23

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

H72

TGA 26/33.D28 26/33.D28 6X6 BL

H24

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

H73

TGA 35/41.D28 35/41.D28 8X6 BB

H25

TGA 26/33.D28 26/33.D28 6X4 BB

H74

TGA 28.D20 6X2-4 BL

H26

TGA 26/33.D20 26/33.D20 6X4 BB

H75

TGA 28.D20 6X2-4 LL

H27

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

H76

TGA 35/41.D28 35/41.D28 8X8 BB

H28

TGA 33.D28 6X4 BB-WW

H80

TGA 18.D20 4X4 BL

H29

TGA 26/33.D28 26/33.D28 6X4 BL

H81

TGA 28.D28 6X4-4 BL

H30

TGA 26/33.D20 26/33.D20 6X4 BL

H82

TGA 26/33.D20 26/33.D20 6X6 BL

H31

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

H84

TGA 28.D20 6X4-4 BL

H32

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

H85

TGA 28.D20 6X2-2 LL

H33

TGA 40.D28 6X4 BB-WW

H86

TGA 28.D28 6X2-2 BL

H34

TGA 40.D20 6X4 BB-WW

H87

TGA 28.D28 6X2-2 LL

H35

TGA 26.D20 26.D20 6X4H BL-2, 6X4H-4 BL

H88

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

H36

TGA 35.D28 8X4 BB

H89

TGA 28.D20 6X2-2 BL

H37

TGA 35.D20 8X4 BB

H90

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

H38

TGA 41.D28 8X4 BB

H91

TGA 35.D28 8X4-4 BLL

1-6

T 69

INTRODUCTION

Model Model designation

Model Model designation

H39

TGA 41.D20 8X4 BB

H92

TGA 35.D20 8X4-4 BLL

H40

TGA 32/35.D28 32/35.D28 8X4 BL

H93

TGA 35/41.D20 35/41.D20 8X6 BB

H41

TGA 32/35.D20 32/35.D20 8X4 BL

H94

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

H42

TGA 26.D20 26.D20 6X4H 6X4H BL/2, BL/2, 6X4H/4 6X4H/4 BL

H95

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

H43

TGA 19.D28 4X2 BBS-WW

H96

TGA 35/41.D20 35/41.D20 8X8 BB

H44

TGA 24.D28 6X2-2 LL-U

H99

TGA 28.D20 28.D20 6X2-4 6X2-4 LL-LOW LL-LOW ENTRY ENTRY

Trucknology Trucknology Generation L (N01-N99) (N01-N99) Model Model designation

Model Model designation

N01

TGL 7,5.D08 4X2 BB (R4)

N11

TGL 7,5.D08 7,5.D08 4X2 4X2 BL (R4)

N02

TGL 8.D08 4X2 BB ((R6) R6)

N12

TGL 8.D08 4X2 BL BL (R6) (R6)

N03

TGL 8.D08 4X2 BB ((R4) R4)

N13

TGL 8.D08 4X2 BL BL (R4) (R4)

N04

TGL 12.D08 4X2 BB BB (R6) (R6)

N14

TGL 12.D08 4X2 BL (R6)

N05

TGL 12.D08 4X2 BB BB (R4) (R4)

N15

TGL 12.D08 4X2 BL (R4)

Trucknology Trucknology Generation M (N01-N99) (N01-N99) Model Model designation

Model Model designation

N08

TGM 18.D08 4X2 BB (R6) (R6)

N34

TGM 13.D08 4X4 BL-FW BL-FW (R6) (R6)

N16

TGM 15.D08 4X2 BL (R6)

N36

TGM 13.D08 4X4 BL BL (R6) (R6)

N18

TGM 18.D08 4X2 BL (R6)

N38

TGM 18.D08 4X4 BB BB (R6) (R6)

N26

TGM 15.D08 4X2 LL (R6)

N48

TGM 26.D08 6X4 BB BB (R6) (R6)

N28

TGM 18.D08 4X2 LL (R6)

T 69

1-7

INTRODUCTION EXPLANATORY NOTES TO THE WIRING DIAGRAMS

1

2

3

4

5 6

1-8

Electric Electrical al compone component nt design designati ation on (exa (exampl mple: e: diod diode e V100 V100 on the cent central ral electrical system, number 53) Instal Installat lation ion positi position on on the front front of the central electrical electrical system (here: stamped number 53) Instal Installat lation ion positio position n on the rear rear of the central electrical electrical system (here: connector  connector  78, connection 8) Cabl Cable e desi designa gnatio tion, n, numbe numberr, with abbreviated colour name in the case of  coloured cables, cross section information only given if different from 12 Cable designation, designation, number in brackets: brackets: conductor pathways on a p.c.b. Line interruption interruption with information information about where where the line continu continues, es, with with sheet sheet number number (here (here:: shee sheett 2 – not page page numbe number) r) and path number (here: path 4)

7 8

9

T 69

Plug Plug connec connectio tion n (exampl (example: e: 1-pin 1-pin plug plug connection X104) Instal Installat lation ion locatio location n of the compon component ent (see (see:: ide identi ntification cationss of instal installat lation ion positions) Current path (numbered (numbered from 1 to 55/60 on each diagram)

INTRODUCTION Installation positions for location identifiers Installation Installation positions positions for left-hand drive vehicles (TGL/TGM/TGA) (TGL/TGM/TGA)

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

Rear of vehicle Engine Gearbox Front of vehicle Bumper   Entrance, right Entrance, left Area Area of cent centra rall elec electr tric ical al syst system em Contr ontrol ol unit unit plug plug-i -in n modu module less Back wall of cab Dashboard Mid-section Stee Steeri ring ng colu column mn/s /ste teer erin ing g whee wheell Pedals Fro Front wall inside left Fron ront wall inside right Driver's seat Co-driver’s r’s seat Shift console Battery box B-pi B-pillllar ar,, driv driver er's 's side side

H2 J1 J2 L N P R1 R2 S1 S2

T 69

A-p A-pililla larr, dri driver' ver'ss side side B-pi B-pillllar ar,, co-d co-dri rive ver' r'ss side side A-pi A-pillllar ar,, co-d co-dri rive ver' r'ss side side Ceiling/roof   Front axle Rear axle Fron Frontt fram frame e sections Rear frame section Door, left Door, right

1-9

INTRODUCTION Installation Installation positions for right-hand right-hand drive vehicles (TGL/TGM/TGA) (TGL/TGM/TGA)

 A B1 B2 C C1 C2 C3 E6 E7 E8 F F1 F2 F3 F4 F5 F6 F7 F8 G H1 H2 J1 1 - 10

Rear of vehicle Engine Gearbox Front of vehicle Bumper   Entrance, right Entrance, left Area Area of cent centra rall elec electr tric ical al syst system em Cont Contro roll uni unit plug plug-i -in n modu modulles Back wall of cab Dashboard Mid-section Stee Steeri ring ng colu column mn/s /ste teer erin ing g whee wheell Pedals Fron ront wall inside left Fron ront wall inside right Co-driver’s r’s seat Driver's seat Shift console Battery box B-pi B-pillllar ar,, co-d co-dri rive ver' r'ss side side A-pi A-pillllar ar,, co-d co-dri rive ver' r'ss side side B-pi B-pillllar ar,, driv driver er's 's side side

J2 L N P R1 R2 S1 S2

T 69

A-pi A-pillllar ar,, dri driver' ver'ss side ide Ceiling/roof   Front axle Rear axle Fro Front frame ame sect ections Rear frame section Door, left Door, right

DEVICE DESCRI DESCRIPTION PTION

DEVICE DESCRIPTION SYSTEM DESCRIPTION DESCRIPTION General information information

The climate required inside motor vehicles is determined by the people and goods carried in the vehicle. Particular attention should be paid to the driver of the vehicle from a road safety point of view. The ability of a person to concentrate is negatively affected by poor atmospheric conditions such as high temperatures, high atmospheric humidity and pollution caused by dust, noise and odours. These effects can be largely negated by passing the internal air through a climate control system. Air-conditioning system

 Air-conditioning systems are installed in vehicles in order to provide a pleasant climate for drivers and passengers in conjunction with the heating and ventilation system. Other advantages of the air-conditioning system relate to its properties of cleaning and drying the air entering the interior of the vehicle. This has the side effect of enabling a fogged-up windscreen and windows to be demisted more rapidly. The following following additional additional characteristics characteristics differentiate differentiate the controlled air-conditioning air-conditioning system from the heater:  –  A motor-actuated heater element bypass

flap

provides temperature-controlled air from the ventilation

nozzles  –  The air outlet temperatures and the air volume are controlled according to the ambient temperature and the nominal value selected by the driver   –  The air-conditioning control is integrated in the control element and only has to be electrically connected to the vehicle electrical system high-performance ce heater blower with motor and adapted, infinitely variable blower controller   –  A high-performan  –  The evaporator with expansion valve and de-icer are integrated in the  fi lter housing for the air-conditioning system system with condensation condensation drain  –  A pollen filter (hybrid filter comprising filter mat and activated charcoal) is installed on the inlet side of the evaporator. This filters particles, gases and odours out of the air and permanently absorbs a proportion of  them. The  fi lter system functions both in fresh air and recirculating air modes. external temperature sensor is integrated in the vicinity vicinity of the fresh air induction induction port  –  The external electrical ical connec connectio tion n between between the heater heater and filter lter housi housing ng is made made usin using g 2 wate waterp rproo rooff plug plug conne connect ctio ions ns  – The electr providing reliable contact

T 69

2 - 11

DEVICE DESCRIPTION Refrigerant circuit and its components

1 2 3

Evaporator   Expansion valve Fluid tank with dryer 

4 5

Condenser   Compressor  

When the vehicle vehicle’s ’s engine engine is running running and the air-con air-condit dition ioning ing system system is switch switched ed on, the refrige refrigerant rant circulates through components (1) to (5) that are connected together by hoses and pipelines. The refrigerant continuously continuously changes changes between liquid and gaseous gaseous states in this process. Heat is extracted from the air  evaporator.. The cooled air is distributed to the interior of the vehicle by the heating and flowing through the evaporator ventilation system. The required volume of refrigerant is controlled by the expansion valve.

2 - 12

T 69

DEVICE DESCRI DESCRIPTION PTION FUNCTIONAL DESCRIPTION Function diagram of the refrigerant circuit

1 2 3 4 5 6 7 8 9

Evaporator   Expansion valve High/lo /low-press essure switch itch on fluid tank (B203) Valve – Liquid fill only on pressure side (large valve diameter) diameter) Fluid tank with dryer  Condenser   Compressor with magnetic coupl upling ing (Y114) Valve – Gaseous  fi ll only on induction side (small valve diameter) Evaporator sensor  

10 11 12 13 14 15 a b c d

Solen Solenoi oid d valv valve, e, air-c air-con ondi diti tion onin ing g syst system em at front end (Y117) Inte Intern rnal al airair-co cond ndit itio ioni ning ng temp temper erat atur ure e sensor (B393) Exte Extern rna al temp tempe eratu rature re sens sensor  or  Heat exc exchang anger sensor  nsor  Push Pushbu butt tto on swi switch, tch, airair-co cond ndit itiioni oning system Cont Contro roll elem elemen ent, t, cab cab heat heatin ing g (A47 (A474) 4) High pressure – fluid High pressure – gaseous Low pressure – fluid Low pressure – gaseous

Description of the refrigerant circuit

The air-conditioning system operates according to the principle of the compression refrigeration system in which the circulating circulating refrigerant is first compressed in gaseous form, then condensed by the dissipation of  heat and  fi nally re-evaporated re-evaporated by reducing reducing the pressure pressure with the application application of heat. When the refrigerant refrigerant circuit is set in operation, i.e. the air-conditioning air-conditioning system system is switched on using the “air-conditioning system pushbutton switch” (14) when the vehicle’s engine is running, the compressor (7) draws cold gaseous refrigerant from the evaporator (1). Refrigerant is compressed, during which process it is T 69

2 - 13

DEVICE DESCRIPTION

heated to about 65 – 105 °C. After this, it is pumped pumped into the condenser condenser (6). There, the the hot, compresse compressed d gas is cooled by the slipstream. slipstream. The gas condenses when the dew point is reached (this depends on the pressure, e.g. 50 °C at 13 bar pressure for refrigerant R 134a). The resulting resulting liquid refrigerant refrigerant passes through the fl uid tank (5) and is dried as it does so. Any moisture moisture or impurities impurities are filtered out by the integrated desiccant insert.  At a pressure of about 2 bar, the high/low-pressure switch on the fluid tank (B203) interrupts the circuit to the compressor compressor magnetic coupling coupling (7). This means the compressor compressor is immediately immediately decoupled decoupled if there is a pressure loss in the system. The pressure switch also switches off the compressor via the magnetic coupling if the system overheats, e.g. poor heat dissipation dissipation from the condenser (condenser (condenser contaminated), contaminated), which would result result in a pressure of about 26 bar in the system. system. The refrigerant refrigerant under high pressure continues continues to flow from the  fl uid tank (5) to the expansion valve (2). It is sprayed into the evaporator (1) at the expansion valve (low-pressure section). Here, the liquid refrigerant expands and evaporates while absorbing heat. The heat of vaporisation needed for this is taken from the air  fl owing past the evaporation evaporation vanes. As a result, result, this air is cooled and can be used for cooling cooling the inside of the vehicle. The refrigerant refrigerant is now once again in a completely completely gaseous state state and is drawn in again by the compressor compressor (7). The cycle starts over again. Control element, cab heating with air-conditioning system (A474) Connector pin assignment

Plug X1 Pin

Line no.

1

58000

Input

2

—–

—–

3

23309

Output put

4

23112

Input

2 - 14

 

Circuit

 

Designation

Electrical power supply terminal 58 – lighting Not used Solenoi noid valve, airir-conditioning sys system at front end (Y11 Y117 pin 2) Internal air-conditioning temperature sensor (B393 pin 5) T 69

DEVICE DESCRI DESCRIPTION PTION

Pin

Line no.

Circuit

5

59104

Input

6   23 23101 101/23 /23300 300

Output put

Designation

Engine start signal from central computer computer 2 (A302 pin F2/17) High/low-pres High/low-pressure sure switch switch on refrigerant refrigerant tank (B203), magnetic magnetic coupling on compressor (Y114)

7

58300

Input

Electrical power supply terminal 58D – dimmed lighting

8

3101 1012

Output put

9

2420 24201/ 1/16 1620 202 2

Inpu Input/ t/ou outp tput ut

10

25009

Input

11

—–

—–

12

31000

Input

Pin

Line no.

Circuit

Designation

1

Red

Output

Electrical power supply blower terminal 15 – sequence controller 

Green

Input Input

Earth rth, int interna ernall air-condit ditioni ionin ng temperat eratu ure sens ensor (B3 (B393 pin 6) Diagnosis, K-line heater and air-conditioning system control Diagnosis Diagnosis socket (X200) Voltage supply, terminal 15 Fuse, heater blower/air-conditioning system (F397) Not used Ground, terminal terminal 31 Central electrical electrical system (A100 pin G/2)

Plug X2

2

 

Diagn Diagnos osti ticc chec checkb kbac ack, k, blow blower er cont contro rollller  er 

3

Brown

4

Yellow/green

Input

5

Red/white

Output

Checkback evaporator sensor, external temperature sensor, heat exchanger sensor 

6

Yellow

Output

Fresh air/recirculating air  flap motor connection A

7

White/red

Input

8

—–

—–

9

Grey

Output

10

Black

Input

11

Black/white

Output

Reference voltage 5 V

12

Yello ellow w/bl /black ack

Outp Output ut

Heat Heater er elem elemen entt bypa bypass ss flap motor connection A

13   White/yellow

 

Output

Inpu Inputt

Earth blower blower terminal terminal 31 Evaporator sensor  

Checkback potentiometer heater element bypass  fl ap Not used Fresh air/recirculating air  flap motor connection B Heat exchanger sensor  

Exte Extern rnal al temp temper erat atur ure e sens sensor  or 

14

Violet

Output

Voltage blower control

15

Grey/red

Output

Heater element bypass flap motor connection B

External temperature sensor 

The measured external external temperature temperature provides the basic parameter parameter used in the control function. function. Further  adaptation adaptation of the heating/cooling heating/cooling power and the blower is then performed using the other sensors. Evaporator Evaporator sensor 

The evaporator sensor measures the evaporator temperature and is used for regulating the required cooling power power.. No regulati regulation on takes place place at temperatu temperatures res below below 0 °C, to protect protect agains againstt icing. icing. This This is done by switching switching the refrigerant refrigerant compressor off and on. Heat exchanger sensor (blow-out air temperature sensor)

The electronic control unit calculates a blow-out air temperature depending on the required heating power. This temperature is set by activating the water timing valve by means of a water  fl ow volume control.

T 69

2 - 15

DEVICE DESCRIPTION Internal Internal air-conditioni air-conditioning ng temperature temperature sensor (B393)

Connector pin assignment Pin

Line no.

Designation

1

23335

Blower motor +24 V – X1560 relay socket

2

3100 31000 0

Blow Blower er motor otor eart earth h – X254 X2541 1 pote potent ntia iall dist distri rib butor utor 21-p 21-pin in liline ne 3100 31000 0

3 and 4

—–

5

23112

NTC NTC 10 kΩ  – Cab heating control element with air-conditioning system at about 25 °C

6

31012

NTC NTC 10 kΩ  – Cab heating control element with air-conditioning air-condition ing system at about 25 °C

Not used

oning temperature sensor measures measures the actual air-conditioning Nominal/actual Nominal/actual value comparison: comparison:  The internal air-conditi internal temperature. This control parameter param eter is the most important one, since it is the only one that measures internal al tempera temperatur ture e influences uences all automat automatical ically ly contro controllab llable le heating heating the ambien ambientt condit conditions ions for the driver driver.. The The intern components (solenoid valve air-conditioning air-conditioning at front-end, magnetic coupling compressor, blower). Setting the nominal value:  Nominal values from 16 °C to 32 °C can be set for the internal temperature. The

nominal value set on the control element is also corrected by the control system depending on the external temperature. A higher internal temperature is set when the external temperature is low and vice versa. The middle position (internal temperature dial, item 22) is felt to be comfortable by a majority of users (subjective assessment). assessment). The monitoring (MAN-cats) (MAN-cats) displays 24 °C. The left side of the dial (which must be turned to the last stop) switches the heating off and sets the air-condition air-conditioning ing system to maximum power. The right side of the dial (which must also be turned to the last stop) sets the heating to maximum power and switches the air-conditioning system off. The automatic blower  control continues to be adjusted depending on whether 16 °C or 32 °C is set. Selecting Selecting between air-conditioning air-conditioning system modes AC or REHEAT

In AC, the air-conditioning system system is controlled according to the variable evaporator temperature. This means the temperature of the air emerging emerging from the air-conditioning system at the heat exchanger sensor and in the interior is controlled by the the switch-on time of the compressor or by cycling the water valve. In this setting, the ally switches switches between between cooling, ventilating ventilating and heating. heating. At moderate external external air-conditioning control automatic control automatically  is moist, the humid air may cause the climate inside the cab to be uncomfortable temperatures when the air  is in spite of the fact that the the selected internal temperature is being maintained. Select REHEAT in this case. In REHEAT, REHEAT, the AC system is set set to evaporator temperatures between 2 and 7 °C while the internal temperature causes some of the humidity in the air to condense out and escape escape is set by additional heating. hea ting. Cooling causes through the water drain. drain. Subsequent heating means the air inside the cab will be dryer. The REHEAT setting temperatures up to about 5 °C for demisting demisting the windows more rapidly. rapidly. AC can also be used at external external temperatures control consumes less less fuel than REHEAT because the compressor switches on less frequently.

2 - 16

T 69

DEVICE DESCRI DESCRIPTION PTION Heater element bypass

flap

The bypass  fl ap (1) makes it possible to have a parallel air  fl ow that is not passed over the heating system’s heat exchanger exchanger.. The flap is fully opened when the air-conditioning system is operating in order to allow the greatest possible air  flow rate. rate. The flap is closed during REHEAT mode in order to allow for even dehumid dehumidify ifying. ing. During During heating heating mode, mode, the flap posi positio tion n is infinitely nitely variabl variablyy contro controlle lled d depend depending ing on the required required heat output (full heating power = flap closed / heating off = flap fully open). This means additional fresh air  is directed to the central central nozzles. As a result, the temperature temperature distribution distribution in the cab is improved improved (warm feet  – cool head). The direct admixture of fresh air at the central nozzles means that they are subject to greater  temperature fluctuations than the other air outlets. Compressor with magnetic coupling (Y114)

The compressor installed in the vehicle provides the drive for the air-conditioning system and represents one of the boundaries boundaries between the high and low-pressure low-pressure sides of the refrigerant circuit. circuit. The compressor draws cold refrigerant refrigerant gas from the evaporator (on the low-pressure low-pressure side) and compresses it. This process causes the refrigerant to heat up, after which it is pumped into the condenser condenser (high-pressure (high-pressure side). The magnetic coupling (Y114) switches switches the compressor compressor on and off. Magnetic coupling switched off 

1 2 3 4

Belt sheave Electromagnet Anchor plate Spring plate

T 69

2 - 17

DEVICE DESCRIPTION Magnetic coupling switched on

Fluid tank Fig. TGL/TG TGL/TGM M

The fluid tank (1) is integrated in the condenser. Fig. Fig. TGA TGA

From the condenser, the refrigerant flows into the fluid tank (1) in which a reserve of refrigerant is held in readiness to compensate for variations in the demand for refrigerant by the evaporator. The built-in  fl uid tank is on the high-pressure side of the refrigerant refrigerant circuit and installed installed after the condenser. condenser. The job of the fluid tank is to collect the liquid refrigerant from the condenser and to bind up any moisture which the refrigerant may contain. contain.

2 - 18

T 69

DEVICE DESCRI DESCRIPTION PTION High/low-pressure switch on refrigerant tank (B203)

 A high/low-pressure switch (1) is installed after the  fluid uid tank tank in orde orderr to monit monitor or or lilimi mitt the the pres pressu sure re cond condit itio ions ns in the enclosed refrigerant circuit. This pressure switch (1) switches off the compressor via the magnetic coupling if the pressures in the system are at impermissible levels, thereby protecting the system against follow-on damage. If the system pressure is less than about 2 bar, as can be caused for example by insuf ficient refrigerant in the circuit, the high/low-pressure switch opens and switches off the compressor. If the system pressure rises very high, as can be caused for example by a contaminated condenser, the high/low-pressure switch switches the compressor off at about 26 bar. Thermostatic Thermostatic expansion expansion valve

The thermostatic expansion valve also forms one of the boundaries between the high and low-pressure parts of the refrigerant circuit. It is installed in front of the evaporator and con figured as a block valve. The expansion valve (also referred to as the injector valve) ensures the optimum amount of refrigerant is injected into the evaporator evaporator.. The injection system system is a closed-loop closed-loop control system. system. This control loop is formed by the interaction of:  –  pressure of the temperature sensor   –  low pressure at the evaporator output  –  spring pressure

The following applies when the system is in equilibrium: Pressure of temperature sensor = Low pressure at evaporator output + spring pressure

1 2 3 4 5

Pressure sensor   Diaphragm Temperature sensor  Pin Ball

6  A B C D

Spring To compressor  From evaporator   From condenser   To evaporator  

The comp compre ress ssor or draw drawss in the the refr refrig igera erant nt and and the the pres pressu sure re in the the evapor evaporat ator or there therefo fore re drop drops. s. This This low low pres pressu sure re acts on the diaphragm (2) and pulls it downwards. This movement is transmitted via the pin (4) to the ball (5). T 69

2 - 19

DEVICE DESCRIPTION

This opens the valve aperture against the spring pressure and the pressurised liquid refrigerant flows into the evaporator evaporator where it can evaporate. evaporate. Once the refrigerant refrigerant has flowed through the evaporator and through through the expansion valve, the medium in the temperature sensor (3) picks up the low temperature resulting from evaporation evaporation and contracts (reduction (reduction in volume). This means the pressure in the temperature sensor is reduced. reduced. The temperature temperature sensor and the pressure sensor (1) are filled with a medium. medium. The medium is a liquefied gas or adsorbent adsorbent which liberates gas when there is a rise in temperature. This causes the balance of forces on the ball (5) to change, and the ball is then pressed upwards by the spring pressure. The injection volume is thereby reduced slightly until the forces are once again in equilibrium. equilibrium. This governing system of the thermostatic expansion valve guarantees superheating of the refrigerant. Refrige Refrigerant rant superhe superheatin ating g is underst understood ood to mean mean the differ differenc ence e betwee between n the theoreti theoretical cal evapora evaporatio tion n tempera temperature ture at the partic particular ular pressu pressure re and the tempera temperatur ture e measured measured after after the evapora evaporator tor (sensor  (sensor  temperature). The overheating setting for this expansion valve is 2.8°C. This mechanism prevents too much refrigerant from being injected into the evaporator since this would mean that not all the refrigerant can evaporate. evaporate. Under these circumstances circumstances,, the compressor compressor would drawn in some liquid refrigerant refrigerant and could be damaged by fluid knocks. Evaporator 

1 2

Evaporator   Injector tubes

3 4

Intake line Expansion valve

The evaporator is installed in the housing of the air-conditioning system directly after the intake openings for  fresh air or recirculating air. Its function is to cool down and dry the warm air in order to control the climate inside the vehicle. vehicle. The evaporator evaporator is the second heat exchanger in the refrigerant refrigerant circuit. circuit. The evaporator is a six-row unit in a full aluminium design. The liquid refrigerant is injected into the  fi rst row of  the the evapo evapora rator tor thro throug ugh h the expan expansi sion on valve valve and and a total total of 6 inje inject ctor or tube tubes. s. There There it expa expands nds and can evap evapor orat ate e whilst absorbing heat. The necessary heat of vaporisation is taken from the air  flowing past the evaporator  vanes. The air then cools down and sheds moisture. The humidity which condenses on the evaporator vanes is allowed to drain out of the system through a condensation condensation drain. The minimum evaporator evaporator temperature temperature is restricted to about +2 °C in order to prevent icing of the evaporator vanes. Condenser 

The function of the condenser is to liquefy the warm refrigerant refrigerant gas and cool it down. It is arranged in the vehicle vehicle so that the passing slipstream slipstream or the air  fl effect.  fl ow from the engine fan provides a good cooling effect. The compressor pumps hot refrigerant gas at a temperature of 60 – 100 °C into the serpentine pipe system of  the condenser. The large number of condenser vanes forms a large surface area and therefore guarantees a good exchange exchange of heat. The hot gas dissipa dissipates tes its its heat heat to the slipstream slipstream and condenses condenses when its temperat temperature ure reaches reaches a level which which is dependent on the pressure (dew point). The liquid refrigerant refrigerant emerges from the condenser and is pumped on to the liquid tank. Connection valves

The system can be filled with refrigerant refrigerant or drained via the connection connection valves. Pressure gauges gauges can be connected connected in order to check the system. The connection connection valves are configured as needle valves. 2 - 20

T 69

DEVICE DESCRI DESCRIPTION PTION

1

Coupling element

2

Needle valve

There are different sizes of connection valve in order to avoid mix-ups between connection valves. Fig. TGL/TGM TGL/TGM

Fig. Fig. TGA TGA

1

Small valve:  Intake side – low-pressure

side

2

Pres Pressu sure re side side – high-pressure side Large Large valv valve: e:

The connection valves are located behind the front cover. The plugs have to be removed from the connection valves. Refrigerant R 134a

The medium used for the evaporation process in air-conditioning systems is a substance with a low boiling point point.. It is refer referre red d to a refrig refriger erant ant.. It is know known n that that wate waterr, for for exam exampl ple, e, boil boilss at lowe lowerr tempe temperat ratur ures es the the lowe lowerr the the pressur pressure. e. All homog homogeneo eneous us liquid liquidss behave behave in the same same way. way. Reduci Reducing ng the pressu pressure re has the the effect effect of reducin reducing g the boiling boiling point, point, and vice versa. versa. The refrigera refrigerant nt (tetrafluoroethylene) R 134a is a partially halogenated T 69

2 - 21

DEVICE DESCRIPTION

substance from the group of  fluorocarbon uorocarbon compounds (chemical formula CF3CH2F), with a boiling boiling point at 26.5 °C. Partially Partially halogenated substances substances only have a brief existence in the atmosphere. atmosphere. Since they do not contain chlorine, chlorine, they do not attack the ozone layer. Furthermore, Furthermore, their contribution contribution to the greenhouse greenhouse effect effect is relatively relatively slight. Refrigerant Refrigerant R 134a is colourless colourless and has a slight odour of ether. ether. Highly irritant irritant decomposition products (vapours) can result in contact with fire or hot surfaces. The substance can form an explosive explosive mixture with air. It decomposes to form hydrohalogens hydrohalogens and carbonyl halides. Concentrations Concentrations of R 134a in the atmosphere atmosphere which are significantly in excess of the TLV can have an anaesthetic effect. TLV value: Threshold  L imit  V alue for concentration of substances in the air, e.g. 1000 ml/m³. Inhaling the

decomposition decomposition products products of R 134a in high concentrations concentrations can lead to shortage shortage of breath. breath. Evaporation Evaporation of the refrigerant on the skin leads to freezing at the points of contact. Maintenance Maintenance note

Various manufacturers offer recycling devices for maintaining and repairing air-conditioning systems filled with R 134a. These are used for evacuating the refrigerant circuit, recycling and checking the refrigerant and refilling the circuit. This ensures that the used refrigerant can be completely re-used.  It must not be vented into the atmosphere. Refrigerant Refrigerant oil fill volume

The oil required for lubricating the refrigerant compressor is in the circuit with the refrigerant and collects in the components components when the system is inoperative. inoperative. As a result, result, whenever components components are renewed renewed together  with the refrigerant, a small quantity of oil must always be added as well. Make sure that only oils authorised for use with the relevant refrigerants and systems are filled. Never mix different oils.  Air-conditioning system oils are hygroscopic, h ygroscopic, meaning that they absorb moisture from the water vapour in the air. air. As a result, result, never store air-conditionin air-conditioning g system oil in open containers! containers! Topping up after repairs or renewing components  Refrigerant compressor: compressor: Flush the system to remove a large proportion proportion of the residual oil. The basic oil fi ll  –  Refrigerant

of the new compressor is suf ficient, there is no need to add extra oil.  –  Condenser: 20 cm3  – Refrigerant tank: 10 cm3  –  Evaporator: 30 cm3  –  Refrigerant hoses: 10 cm3 per metre  –  In case of sudden drainage of the system, e.g. burst hose: 50 cm 3 Filling air-conditionin air-conditioning g systems high-pressure and low-pressure low-pressure lines 1  Extract the  fl uid from both sides of the system via the high-pressure 2  Drain the used oil 3  Evacuate the system (minimum 30 minutes) 4  Check the vacuum high-pressure line line (refer to the Maintenance Maintenance Recommenda Recommendations tions or Operator’s Operator’s Manual 5  Fill the system via the high-pressure for information about the fill volume).  The volume in filler hoses can be ignored! high-pressure hose into the system using low pressure. 6  After  filling, draw the residual fluid in the high-pressure Important! Comply with the following procedure when doing this:  –  Close both stop valves (high pressure, low pressure) on the control panel.  –  Start the engine, switch on the air-conditioning system.  –  Pressure-test the system using the high-pressure and low-pressure gauges on the control panel.  –  Close the service connection on the high-pressure side.  – Slowly, one after the other, open the low-pressure and high-pressure stop valves on the control panel

(this draws the remaining volume into the system)!  –  Close the service connection on the low-pressure side.  – Disconnect both hoses.

2 - 22

T 69

DEVICE DESCRI DESCRIPTION PTION DESCRIPTION DESCRIPTION OF COMPONENTS COMPONENTS Control element, cab heating with air-conditioning system (A474) Design

1 2 3 4

Side Side wind indow ventilati ation dial ial AC-O AC-ON N pushb ushbut utto ton n switc witch h (S54 (S544) 4) Inte Intern rnal al temp tempe eratu rature re dial dial (S546 S546)) Push Pushbu butt tton on swit switch ch,, fres fresh h air/ air/re reci circ rcul ulat atin ing g air (S123)

5 6 7

Blower dial (S547) Air distribution dial “REHEAT” pu p ushbutton (de-humidify) (S545)

sw switch

Installation position

The control element for the cab heating and air-conditioning air-conditioning system (1) is located in the instrument instrument panel.

T 69

2 - 23

DEVICE DESCRIPTION High/low-pressure switch on refrigerant tank (B203) Design

The high/low-pressur high/low-pressure e switch is installed on the out flow end of the fluid tank. Installation Installation position, position, TGL/TGM

Installation position, TGA

The high/low-pressure high/low-pressure switch (1) is located on the front left bulkhead.

2 - 24

T 69

DEVICE DESCRI DESCRIPTION PTION Compressor with magnetic coupling (Y114) Design

1

Belt sheave

2

Magnetic coupling

Installation position

The compressor with magnetic coupling coupling (1) is located on the right-hand side of the vehicle.

T 69

2 - 25

DEVICE DESCRIPTION Solenoid valve, air-conditioning system at front end (Y117) Design

 A

Direction of  flow

B

“RED” cable: Chamber 1; “BROWN” cable: Chamber 2

Installation Installation position, position, TGL/TGM

Installation position, TGA

The solenoid valve for the air-conditio air-conditioning ning system at the front end (1) is located on the front left bulkhead. 2 - 26

T 69

DEVICE DESCRI DESCRIPTION PTION Condenser  Design

The condenser condenser liquefies or cools the hot refrigerant gas. Installation position

The condenser (1) is located on the inlet inlet side of the radiator.

T 69

2 - 27

DEVICE DESCRIPTION Temperature sensor, internal air-conditioning (B393) Design

The internal air-conditioning temperature sensor measures the actual internal temperature. Installation Installation position

The internal air-conditioning temperature sensor (1) is located behind the console in the central part.

2 - 28

T 69

DEVICE DESCRI DESCRIPTION PTION External temperature sensor  Design

The external temperature sensor measures the external temperature. Installation position

The external temperature temperature sensor (1) is installed in the bottom part of the blower blower behind the front cover. cover.

T 69

2 - 29

DEVICE DESCRIPTION Evaporator Evaporator sensor  Design

The evaporator evaporator sensor measures the evaporator evaporator temperature. Installation Installation position

The evaporator sensor (1) is located in the evaporator. The evaporator sensor is shown slightly slightly pulled out in the diagram diagram for ease of interpretation interpretation..

2 - 30

T 69

DEVICE DESCRI DESCRIPTION PTION Heat exchanger sensor (blow-out air temperature sensor) Design

The electronic control unit calculates a blow-out air temperature depending on the required heating power. Installation position

The heat exchanger sensor (1) is located in the air-conditioning system blower.

T 69

2 - 31

DEVICE DESCRIPTION DIAGNOSIS General information information

Most control units testable using MAN-cats are connected with diagnosis socket X200 pin 3 / 4 via a K-line. The diagnostic system stimulates a specific control unit via the K-line. The control unit replies and digitally transfers the faults stored in the fault memory via the K-line. "KWP-on-CAN" control units such as TBM and ECAS2 do not have a K-line. Control units with KWP-on-CAN diagnosis diagnosis are stimulated stimulated by the vehicle management computer computer K-line. The vehicle management computer  computer  opens a gateway to the control unit in question via the CAN. System structure of K-lines TGL/TGM

Central on-board computer 2 (ZBR2) A302 A312   Customer-specified control module Gearbox control, Tipmatic/AS-TRONIC A330 Vehicle management computer  A403 A407   Instrumentation Electronic diesel control A435 Door module, driver side A451 A452 Door module, module, co-driver co-driver side Air-conditioning system A474 Auxiliary air heater  A483 Auxiliary water heater  A494 Control Control unit, EMOS (on gearbox) gearbox) A590 Further systems systems can can be be networke networked d A.. . Diagnosis socket X200 2 - 32

X2544

T 69

Potential distributor, 21-pin, K-line

DEVICE DESCRI DESCRIPTION PTION TGA

Electronicall Electronicallyy controlled controlled air air suspensio suspension n (ECAS) ECAS2 ECAS2 has has KWP-o KWP-onn-CAN CAN Note: diagnosis Control, Control, retarder retarder / Intarder  A144 Control Control unit, unit, torque torque converter converter and and clutch clutch A266 system/retarder  Central Central on-board on-board computer computer 2 (ZBR2) A302 A312   Customer-specified control module Gearbox control, Tipmatic/AS-TRONIC A330 A402 Electronic braking system A403 Vehicle management computer  A407   Instrumentation Electronically controlled air management A409 Electronic diesel control A435 Door module, driver side A451 Door module, co-driver side A452 Air-conditioning system A474 Control Control unit, ACC A479 Auxiliary Auxiliary air heater  A483 A143

T 69

A486 A494 A688 A713 A .. . X200 X2544

Control unit, airbag Auxiliary water heater  Addit Additio iona nall vehi vehicle cle compu compute terr (for  (for  heavy-duty tractor only) Control Control unit in distributor distributor unit Further systems can be networked Diagnosis socket Potential distributor, 21-pin, K-line

2 - 33

DEVICE DESCRIPTION Diagnosis socket (X200)

The SPN fault codes can be downloaded from the fault 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 middle points to pin 1

A

Connector pin assignment Diagnosis socket X200

Address

Pin

Function

Terminal

Line number  

1

Opti Option: on: HD-OB HD-OBD D CAN CAN High High

not used (186)

2

Opti Option: on: HD-OB HD-OBD D CAN CAN Low Low

not used (185)

4

K-line KWP 2000

16202

via X2544 to the contr control ol unit unitss

9

Negative potential

31

31000

Earthin Earthing g point, point, central central elec electri trica call syst system, em, X1644 X1644 via via X1829 X1829

10

Voltage supply

30

30009

via X1535 535 to fuse F41 F412 / 10A

A2/1 2/11

11

Voltage supply

15

16000

via X1 X1833 to to fu fuse F3 F376 / 10 10A

F/3

12

Signal, alternator

W

59101

Alternator G102 pin 1

 

from

ZE Pin

Diagnosis socket HD-OBD (X200)

 As of 01.01.2005, all vehicles with Euro 4 engines are legally required to have a standardised diagnosis interface to ISO 15031-3. In the case of MAN vehicles, the required HD-OBD diagnosis socket will be introduced into production for  the first vehicles from 01.10.2004 01.10.2004 (not for all vehicles at the same time). HD-OBD stands for Heavy Duty On Board Diagnosis. Diagnosis. Heavy-duty Heavy-duty here in the sense of heavy-duty heavy-duty commercial vehicles. vehicles. The installation position and the position designation (X200) remain unchanged as this diagnosis socket replaces the previous one.

2 - 34

T 69

DEVICE DESCRI DESCRIPTION PTION Table for connector pin assignment Pin

Line number

F u nct i o n

1

59101

2

—-

3

16202

K-line

4

31000

Ground, terminal 31

5

—-

Not used

6

186

HD-OBD-CAN high

7

—-

Not used

8

16000

9 - 13

—-

Not used

14

185

HD-OBD-CAN low

15

—-

Not used

16

30009

Speed signal, alternator, term. W Not used

Voltage supply, terminal 15

Voltage supply, terminal 30

Adapter cable, HD-OBD

There is an adapter cable available available for MAN-cats applications. applications. This cable can be ordered by quoting item number 07.98901-0002 07.98901-0002 using the the "MAN-cats "MAN-cats II - spare parts" parts" order order form. All newly ordered ordered diagnosi diagnosiss systems systems come with the adapted cable supplied as standard.

T 69

2 - 35

DEVICE DESCRIPTION Installation positions for diagnosis socket TGL/TGM

The diagnosis socket socket X200 (1) is located located behind a cover below the cup holder on the co-driver's co-driver's side. TGA - old version

The old installation position for the diagnosis d iagnosis socket X200 (1) is on the rear side of the central electrical system. TGA - new version

The new installation position for the diagnosis socket X200 (1) is behind a cover below the cup holder on the co-driver's side.

2 - 36

T 69

DEVICE DESCRI DESCRIPTION PTION Diagnosis socket HD-OBD (X200) for TGA and TGL/TGM

The installation installation position and the position designation designation (X200) remain unchanged unchanged as this diagnosis diagnosis socket (1) replaces the previous one. Main diagnosis functions  –  Fault detection  –  Fault analysis

Occurrence Meaning Identification Fault type (static, sporadic, ...)  –  Fault saving  –  Simulation for troubleshooting Important note: The air-conditioning air-conditioning system does not have a CAN connection, connection, as a result any fault messages that are generated cannot be signalled on the instrumentation. Faults can only be downloaded from the fault memory of the control unit and displayed using MAN-cats II.

T 69

2 - 37

DEVICE DESCRIPTION Troubleshooting program

The following troubleshooting program contains all the faults that can be detected by the fault memory. The sequence of tests corresponds to the numerical succession of fault codes (SPNs), irrespective of the evaluation of the fault. During initial testing, always read out the entire fault memory and document all saved faults (MAN-cats key combination combination CTRL + F11). F11). This is important because because lines and components have to be disconnected disconnected during system troubleshooting, which may cause the corresponding fault messages to be triggered and saved. Consequently, the fault memory should always be deleted after intermediate inspections. If parts are exchanged, send a printout from MAN-cats verifying the fault together with the returned part in order to claim back the costs. (The printout is an extract from the fault memory, see above.) Other procedures are only permitted subject to consultation with the Service Department in Munich! Equal Equally ly,, cont control rol unit unitss are are only only allo allowed wed to be exch exchang anged ed unde underr warr warrant antyy subj subjec ectt to cons consul ulta tati tion on with with the the Servi Service ce Department Department in Munich. Munich. Repeat the test and delete the fault memory after correcting correcting the fault and checking the repair. The fault memory should always be deleted using MAN-cats Alwa Always ys delet delete e the fault fault messa message ge and and obse observe rve the the fault fault befo before re replac replacin ing g any any compo compone nent nt or contr control ol unit. unit. If several faults are entered, always start with the test instructions which do not require components or control units to be replaced. Make sure the ignition is switched off before commencing commencing repairs and replacing components components or control units. Failure to switch off the ignition will lead to fault memory entries (SPNs) in the various electronic control units. Always test the lines in the following order:  –  Discontinuity or contact resistance (e.g. receptacles bent open, connectors or receptacles pushed back or 

corroded corroded plug and socket socket connections) connections)  – Short circuit to negative  – Short circuit to positive  –  Short circuit to adjacent lines  –  Loose contacts  –  Water or moisture in the cable harness Cable harnesses may be damaged or defective even if the corrugated hose appears undamaged on the outside! Break the connection to the control unit before  measuring resistance values.

Refer to the wiring diagrams for the vehicle in question! Resistance measurement  –  Switch the ignition OFF Disconnect the plug at which the measurement measurement is to be taken from the control element.  – Disconnect Voltage measurement  –  Switch the ignition ON element with air-conditioning system.  – The measurement is taken directly on the control element

Voltage is measured with the engine running and the vehicle stationary.

2 - 38

T 69

DEVICE DESCRI DESCRIPTION PTION SPN list (fault codes) and fault code description, control element

The following table lists the fault codes that appear on the instrumentation display or the MAN-cats screen in the event of an fault. The fault causes and responses are documented for the listed fault code descriptions descriptions.. SPN – Suspect  P arameter  Number – Fault location FMI – Failure  M ode Identification – Fault type Address:   98 air-conditioning system Version:   1.80 Note:  See test step list for test step SPN

SPN-Plain text Description

00876

PLAIN TEXT:  Compressor coupling TYPE OF FAULT: 7  – General short circuit CAUSE:  High or low-pressure in refrigerant circuit, defective high/low-pressure switch, defective

compressor coupling, fault in cable line, defective control element. RESPONSE:  Cooling system does not operate or operates permanently. REMEDY:  Check cables, check plug connections, check compressor coupling, check control element element (A474), measure voltage. voltage. Test step: Perform voltage measurement: measurement:

Refrigerant tank, compressor solenoid valve; control element – between pin X1/6 (+) and pin X1/12 (-): 16 - 32V (UBat) Fit a new control element and/or high/low-pressure switch and/or compressor coupling if no fault can be found. 00877

PLAIN TEXT:  Evaporator temperature sensor  TYPE OF FAULT: 5  – Short circuit to ground TYPE OF FAULT: 6  – Short circuit to U bat CAUSE:  Defective evaporator sensor, fault in cable line, defective control element. RESPONSE:  Default value -5°C. Check cables, check plug connections, connections, check evaporator sensor, sensor, check control REMEDY:   Check

element (A474), measure resistance. Test step: Perform resistance resistance measurement: measurement:

 Air-conditioning system evaporator sensor supplied by Behr; control element – between pin X2/4 (+) and pin X2/5 (-): ~= 10 kΩ  at 25 °C Renew control element and/or air-conditionin air-conditioning g system evaporator evaporator sensor supplied supplied by Behr if no fault can be found. 03001

temperature sensor  PLAIN TEXT:  Interior air temperature TYPE OF FAULT: 5  – Short circuit to ground TYPE OF FAULT: 6  – Short circuit to U bat CAUSE:   Defective air-conditioning system temperature sensor, fault in cable line, defective

control element. RESPONSE:  Default value 22°C. REMEDY:  Check cables, check plug connections, check air-conditioning system temperature sensor, check control element (A474), measure resistance. Test step: Perform resistance resistance measurement: measurement:

 Air-conditioning system temperature te mperature sensor; control element – between pin X1/4 (+) and pin X1/8 (-): ~= 10kΩ Renew Renew control control elemen elementt and/or and/or air-co air-condit nditioni ioning ng system system tempera temperatur ture e sensor sensor if no fault fault can be found. found.

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DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03002

temperature sensor  PLAIN TEXT:  External air temperature TYPE OF FAULT: 5  – Short circuit to ground TYPE OF FAULT: 6  – Short circuit to U bat CAUSE:   Defective air-conditioning system external temperature sensor, fault in cable line,

defective control element. RESPONSE:  Default value 0°C. Check cables, cables, check plug connections, connections, check air-conditioning air-conditioning system external external REMEDY:   Check

temperature sensor, check control element (A474), measure resistance. Test step: Perform resistance resistance measurement: measurement:

 Air-conditioning system external temperature sensor supplied by Behr; control element – between pin X2/13 (+) and pin X2/5 (-): ~= 10 kΩ  at 25 °C Renew control element and/or air-conditioning air-conditioning system external external temperature temperature sensor supplied supplied by Behr if no fault can be found. 03003

PLAIN TEXT:  Blow-out air temperature sensor (heat exchanger sensor) TYPE OF FAULT: 5  – Short circuit to ground TYPE OF FAULT: 6  – Short circuit to U bat  Defective air-condition air-conditioning ing system heat exchanger sensor, sensor, fault in cable line, defective CAUSE:  Defective

control element. RESPONSE:  Default value 40°C. REMEDY:  Check cables, check plug connections, check air-conditioning system heat exchanger  sensor, check control element (A474), measure resistance. Test step: Perform resistance resistance measurement: measurement:

 Air-conditioning system heat h eat exchanger exchange r sensor supplied by Behr; control element e lement – between pin p in X2/10 X2/10 (+) and pin X2/5 (-): (-): ~= 10 kΩ  at 25 °C Renew control element and/or air-conditioning air-conditioning system heat exchanger exchanger sensor supplied supplied by Behr  if no fault can be found. 03004

potentiometer  r  PLAIN TEXT:  Bypass flap motor potentiomete TYPE OF FAULT: 5  – Short circuit to ground TYPE OF FAULT: 6  – Short circuit to U bat TYPE OF FAULT: 8  – Defective signal CAUSE: Faults 5 and 6  Defective motor potentiometer, fault in cable line, defective control

element. RESPONSE: Faults 5 and 6  Default value central position. CAUSE: Fault 8  Defective motor potentiometer, bypass  fl ap sticking, fault in cable line, defective

control element. RESPONSE: Fault 8 Motor cannot be moved, unfavourable temperature distribution. feedback REMEDY:  Check cables, check plug connections, check heater element bypass flap feedback

potentiometer, check control element (A474), measure resistance, measure voltage. Test steps: Perform resistance resistance measurement: measurement:

 Air-conditioning system heater element bypass flap feedback potentiometer supplied by Behr; control element – between pin X2/7 (+) and pin X2/5 (-): ~= 95 - 105 k Ω Perform voltage measurement: measurement:

Reference voltage 5 V – air-conditioning system supplied by Behr; control element – between pin X2/11 (+) and pin X2/5 (-): ~= 5 V Renew control element and/or air-conditioning system heater element bypass flap feedback potentiometer supplied by Behr if no fault can be found.

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DEVICE DESCRI DESCRIPTION PTION

SPN

SPN-Plain text Description

03005

PLAIN TEXT:  Heating valve TYPE OF FAULT: 5  – Short circuit to ground TYPE OF FAULT: 6  – Short circuit to U bat CAUSE: Faults 5 and 6  Defective solenoid valve, fault in cable line, defective control element. RESPONSE: Fault 5  Heater does not operate or operates permanently. RESPONSE: Fault 6  Permanent heating. Checkk cabl cables es,, chec checkk plug plug conne connect ction ions, s, chec checkk sole solenoi noid d valv valve, e, EP valv valve, e, REMEDY:   Chec

air-conditioning system at front end (Y117), check control element (A474), measure voltage. Test step: Perform voltage measurement: measurement:

Solenoid valve, EP valve, air-conditioning system at front end – engine must be started; control element – between pin X1/10 (+) and pin X1/3 (-): ~= 0 V solenoid valve closes; 16 - 32 V (U bat) solenoid solenoid valve opens Renew control element and/or solenoid valve, EP valve, air-conditioning system at front end if no fault can be found. 03006

PLAIN TEXT:  Recirculating air  flap motor  TYPE OF FAULT: 7  – General short circuit TYPE OF FAULT: 10  – Interruption CAUSE:  Defective recirculation motor, fault in cable line, defective control element. RESPONSE:  Recirculating air  flap cannot be moved. Check cables cables,, check check plug plug connect connection ions, s, check check air-con air-condit dition ioning ing system system fresh fresh REMEDY:   Check

air/recirculating air  fl  fl ap motor, fresh air position, check control element (A474), measure voltage. Test steps: Perform voltage measurement: measurement:

 Air-conditioning system fresh air/recirculating air  flap motor, fresh air position supplied by Behr; contro controll element element – between between pin X2/6 (+) and pin X2/9 (-): ~= 16 - 32 V (Ubat) operate fresh air  /recirculating air  flap switch (S123); ~= 0 V do not operate fresh air/recirculating air  flap switch (S123)  Air-conditioning system fresh air/recirculating air  flap motor, fresh air position supplied by Behr; contro controll element element – between between pin X2/9 (+) and pin X2/6 (-): ~= 16 - 32 V (Ubat) operate fresh air  /recirculating air  flap switch (S123); ~= 0 V do not operate fresh air/recirculating air  flap switch (S123) Renew control element and/or air-conditioning system fresh air/recirculating air  flap motor, fresh air position supplied by Behr if no fault can be found. 03007

PLAIN TEXT:  Bypass flap motor  TYPE OF FAULT: 7  – General short circuit CAUSE:  Defective motor, fault in cable line, defective control element. RESPONSE:  Motor cannot be moved, unfavourable temperature distribution. Check cables cables,, check check plug plug connect connection ions, s, check check heater heater elemen elementt bypass bypass flap motor, motor, check check REMEDY: Check

control control element (A474), measure measure voltage. voltage. Test steps: Perform voltage measurement: measurement:

Open heater element bypass flap motor – air-conditioning system supplied by Behr; control elem elemen entt – betw between een pin X2/12 X2/12 (+) and pin X2/15 X2/15 (-): (-): ~= -16 - 32 V (Ubat) operate REHEAT pushbutton switch (de-humidify) (S545), REHEAT function activated; brief signal; ~= 16 - 32 V (Ubat) operate REHEAT pushbutton switch (de-humidify) (S545), REHEAT function deactivated; brief signal Close heater element bypass flap motor – air-conditioning system supplied by Behr; control elem elemen entt – betw between een pin X2/15 X2/15 (+) and pin X2/12 X2/12 (-): (-): ~= -16 - 32 V (Ubat) operate REHEAT pushbutton switch (de-humidify) (S545), REHEAT function activated; brief signal; ~= 16 - 32 V (Ubat) operate REHEAT pushbutton switch (de-humidify) (S545), REHEAT function deactivated; brief signal Renew control element and/or air-conditioning system heater element bypass fl ap motor supplied by Behr if no fault can be found.

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DEVICE DESCRIPTION

SPN

SPN-Plain text Description

03008

PLAIN TEXT:  Blower control voltage TYPE OF FAULT: 1  – Signal or value too high TYPE OF FAULT: 2  – Signal or value too low CAUSE:  Defective blower controller, fault in cable line, defective control element. RESPONSE:  Blower is not controlled correctly. REMEDY:  Check cables, check plug connections, check blower controller, check control element

(A474), measure voltage. voltage. Test steps: Perform voltage measurement: measurement:

Electrical power supply to blower dial for blower control (S547); control element – between pin X2/14 X2/14 (+) and pin X2/3 (-): ~= 0 V “OFF” “OFF” position position;; ~= 0 - 10.3 V “AUTO” “AUTO” position position;; ~= 2 - 8.3 V linear range; ~= 10 V “MAX” position Electrical power supply to blower controller terminal 15 – air-conditioning system supplied by Behr; control element – between pin X2/15 (+) and pin X2/3 (-): ~= 16 - 32 V (Ubat) Renew control element and/or air-conditioning system blower dial supplied by Behr if no fault can be found.

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DEVICE DESCRI DESCRIPTION PTION Test step list for air-conditioning system

The test step list enables the components and/or functions of the air-conditioning system to be checked with a multimeter (e.g. FLUKE 77 or 87). Test description

In the test step list presented in this chapter (example: test step 1), the first test contact is designated designated “Pin X1/4” and the second test contact is designated “Pin X1/8”. Use a multimeter to measure the resistance between between these pins. Measure directly directly on the control element for the cab heating with air-conditioning air-conditioning system. The measuring mode to be set on the measuring instrument (multimeter) is shown between test contacts (pins) listed in column 3. Example:

Setting “V” = Voltage measurement

Example:

Setting Setting “Ω” = Resistance Resistance measurement

Once the test requirements have been fulfilled, the value indicated on the measuring device (actual characteristic) can be compared with the desired value (desired characteristic). Two sample measurements are described below:

When measuring voltages, voltages, switch on the ignition and leave the plug of the control control element connected. connected. In this example, example, the electrical electrical power supply to the control element is measured between pin X1/10 – positive line and pin X1/12 – earth line. The measured value obtained using the FLUKE 77 multimeter multimeter is 22.67V (battery voltage). voltage).

When measuring resistance values, switch off the ignition and disconnect the plug at which the resistance value is to be measured.

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DEVICE DESCRIPTION

In this example, example, the resistance resistance on the heat exchanger sensor (supplied by Behr) is measured between pin X2/10 – heat exchanger input signal and pin X2/5 – heat exchanger checkback signal. The value measured with the FLUKE 77 multimeter is 10.67 k Ω. Test step list

SN: ...............................................................

Tester: ..........................................................

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

First registered: registered: .............. .................... ............. ............. ............. ............ .....

Vehicle Vehicle model: ............. .................... ............. .............. .............. ............. .........

Chassis Chassis no.: ............. ..................... .............. ............. ............. .......... ....

Engine model: ............. ................... ............. .............. ............. ............. ............. ........ ..

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

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

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

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

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

Use MAN-cats II to read out the fault memory of the control control element for the cab heating with air-conditionin air-conditioning g system (A474). The test step list is designed to pinpoint the entered entered active faults.  – Use the vehicle-speci fic overviews and wiring diagrams for troubleshooting.  –  Voltage measurements are taken with the ignition switched on, the engine running and the vehicle

stationary.  –  When a resistance is being measured, the ignition is switched off.  –  Voltages and resistances are measured between the + connection (pin +) and the - connection (pin -) on the multimeter (e.g. FLUKE 77 or 87).  – Never measure at the plug contacts themselves without using suitable test probes! Danger of  bending open the contacts! Resistance measurement  –  Ignition OFF  –  Disconnect the plug at which the measurement is to be taken from the control element. Interior air temperature sensor  Cont Contro roll elem elemen entt designation

pin pin

Internal air-condition air-conditioning ing temperature sensor (B393) Line number

Measuring device P in +

Pin-

X1/4

X1/8

23112

31012

 

Desired value [ Ω]

~= 10kΩ

 

Measured value [Ω]

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

Engine start signal Cont Contro roll elem elemen entt designation

pin pin

Engine start signal from from central computer 2 (A302 pin F2/17) Line number

2 - 44

Measuring device P in +

Pin-

X1/5

X1/12

59104

31000

T 69

 

Desired value [ Ω]

~= 9 - 16kΩ

 

Measured value [Ω]

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

DEVICE DESCRI DESCRIPTION PTION Evaporator Evaporator sensor  Contr Control ol elemen elementt pin pin designation

 Air-conditioning system evaporator sensor supplied by Behr (A480) Line colour 

 

Measuring Measuring device P in +

Pin-

X2/4

X2/5

Desired value [Ω]

  Measured value [Ω]

 

~= 10 kΩ at 25 °C Yellow /green

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

Red /white

Checkback Checkback potentiometer potentiometer heater element bypass flap Contr Control ol elemen elementt pin pin designation

 Air-conditioning system checkback checkback potentiometer  potentiometer  heater element bypass flap supplied supplied by Behr (A480) Line colour 

 

Measuring Measuring device P in +

Pin-

X2/7

X2/5

Desired value [Ω]

~= 95 - 105 k Ω White /red

  Measured value [Ω]

 

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

Red /white

Heat exchanger sensor  Contr Control ol elemen elementt pin pin designation

Measuring Measuring device P in +

Pin-

 Air-conditioning system heat exchanger sensor supplied by Behr (A480)

X2/10

X2/5

Line colour

Black

Desired value [Ω]

~= 10 kΩ at 25 °C

  Measured value [Ω]

 

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

Red /white

External temperature sensor  Contr Control ol elemen elementt pin pin designation

 Air-conditioning system external temperature sensor  supplied supplied by Behr (A480) Line colour 

 

Measuring Measuring device P in +

Pin-

X2/13

X2/5

Desired value [Ω]

~= 10 kΩ at 25 °C White /yellow

  Measured value [Ω]

 

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

Red /white

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DEVICE DESCRIPTION Voltage measurement  –  Ignition ON  –  The measurement is taken directly on the control element with air-conditioning system.

Voltage Voltage is measured measured with the engine running and the vehicle stationary. stationary. The operating voltage is approximately 28 V, the operating voltage range is 16 - 32 V. Voltage supply Cont Contro roll elem elemen entt designation

pin pin

Measuring device P in +

Pin-

Electric Electrical al power power supply supply to control control elemen elementt –   terminal front-end d heater heater fuse, fuse, 15   front-en air-conditioning system (F397)

X1/10

X1/12

Line number

25009

31000

X1/1

X1/12

58000

31000

Electric Electrical al power power supply supply to blower controller terminal 15  Air-conditioning system supplied by Behr (A480)

X2/1

X2/3

Line colour

Red

Brown

Electr Electric ical al power power suppl supplyy to blow blower er con control trol dial dial (S547) in  –  “OFF” position

X2/14

X2/3

Line colour

Violet

Brown

Electr Electric ical al power power suppl supplyy to blow blower er con control trol dial dial (S547) in  –  “AUTO” position

X2/14

X2/3

Line colour

Violet

Brown

Electr Electric ical al power power suppl supplyy to blow blower er con control trol dial dial (S547) in  –  linear range

X2/14

X2/3

Line colour

Violet

Brown

Electr Electric ical al power power suppl supplyy to blow blower er con control trol dial dial (S547) in position  –  “MAX” position

X2/14

X2/3

Line colour

Violet

Brown

Electr Electric ical al power power suppl supplyy terminal terminal 58 dimmed  –  when terminal 58 “OFF”

X1/7

X1/12

58300

31000

Electr Electric ical al power power suppl supplyy terminal 58 parking lights Fuse, instrument, switch and pushbutton pushbutton unit illuminatio illumination n (F125) Line number

Line number

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T 69

 

Desired value [V]

 

16 - 32V (UBat)

16 - 32 V (U bat) when parking parking lights lights “ON”; “ON”; operate operate light light switch switch (S111)

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

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

 

16 - 32V (UBat)

 

~= 0 V

Measured value [V]

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

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

~= 0 - 10.3 V

 

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

~= 2 - 8.3 V

 

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

 

~= 10 V

0V

 

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

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

DEVICE DESCRI DESCRIPTION PTION

Cont Contro roll elem elemen entt designation

pin pin

Elect Electri rica call powe powerr suppl supplyy terminal terminal 58 dimmed  –  when terminal 58 “ON” Line number

Measuring device Pin+

Pin-

X1/7

X1/12

58300

31000

 

Desired value [V]

~= 12 V

 

Measured value [V]

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

Solenoid valve air-conditioning system at front end Cont Contro roll elem elemen entt designation

pin pin

Measuring device Pin+

Pin-

Solenoi Solenoid d valve, valve, EP valve, valve, air-conditioning system at front end (Y117) Engine must be started  –  Solenoid valve closes

X1/10

X1/3

Line number

25009

23309

Solenoi Solenoid d valve, valve, EP valve, valve, air-conditioning system at front end (Y117) Engine must be started  –  Solenoid valve opens

X1/10

X1/3

Line number

25009

23309

 

Desired value [V]

~= 0 V

Measured value [V]

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

 

16 - 32V (UBat)

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

Engine start signal Cont Contro roll elem elemen entt designation

pin pin

Engine start signal from from central computer computer 2 (A302 pin F2/17)  –  Engine not running Line number Engine start signal from from central computer computer 2 (A302 pin F2/17)  –  Engine running Line number

Measuring device Pin+

Pin-

X1/5

X1/12

59104

31000

X1/5

X1/12

59104

31000

 

Desired value [V]

~= 0 V

 

Measured value [V]

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

 

16 - 32V (UBat)

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

Refrigerant tank, compressor solenoid valve Cont Contro roll elem elemen entt designation

pin pin

Refrigerant tank, compressor  solenoid valve on refrigerant tank with high/low-pre high/low-pressure ssure switch switch (B203), (B203), magneti magneticc couplin coupling g on compre compressor  ssor  (Y114) Line number 

Measuring device Pin+

Pin-

X1/6

X1/12

Desired value [V]

16 - 32V (UBat) 23101 / 23300

 

 

 

Measured value [V]

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

31000

Note: The evaporator temperature only changes if the engine is running.

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DEVICE DESCRIPTION Fresh air/recirculati air/recirculating ng air  flap motor  Contr Control ol elemen elementt pin pin designation

Measuring Measuring device Pin+

Pin-

X2/6

X2/9

Yellow

Grey

X2/6

X2/9

Yellow

Grey

Fresh air/recircul air/recirculating ating air  recirculating air  flap motor in recirculating position  Air-conditioning system supplied supplied by Behr (A480) Operat ate e fres fresh h air  air   – Oper /recirculatin /recirculating g air flap switch switch (S123)

X2/9

X2/6

Line colour 

Grey

Fresh air/recirculat air/recirculating ing air flap motor in fresh air position  Air-conditioning system supplied supplied by Behr (A480) Operat ate e fres fresh h air  air   – Oper /recirculatin /recirculating g air flap switch switch (S123) Line colour Fresh air/recirculat air/recirculating ing air flap motor in fresh air position  Air-conditioning system supplied supplied by Behr (A480)  –  Do not operate fresh air  /recirculatin /recirculating g air flap switch switch (S123) Line colour

 

 

X2/9

X2/6

Line colour

Grey

Yellow

Heater element bypass flap motor – open  Air-conditioning system supplied supplied by Behr (A480) Operate “REHEA “REHEAT” T”  – Operate pushbut pushbutton ton switch switch (de-humidify) (S545)

X2/12

X2/15

2 - 48

 

Yellow /black

~= 16 - 32 V (Ubat)

~= 0 V

  Measured value [V]

 

 

~= 16 - 32 V (Ubat)

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

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

 

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

Yellow

Fresh air/recircul air/recirculating ating air  recirculating air  flap motor in recirculating position  Air-conditioning system supplied supplied by Behr (A480)  –  Do not operate fresh air  /recirculatin /recirculating g air flap switch switch (S123)

Line colour 

Desired value [V]

Grey /red

T 69

~= 0 V

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

~= 16 - 32 V (Ubat) REHEAT REHEAT function function activat activated; ed; brief  brief  signal

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

DEVICE DESCRI DESCRIPTION PTION

Measuring Measuring device

Contr Control ol elemen elementt pin pin designation

Heater element bypass flap motor – open  Air-conditioning system supplied supplied by Behr (A480) Operate “REHEA “REHEAT” T”  – Operate pushbut pushbutton ton switch switch (de-humidify) (S545) Line colour 

 

Pin-

X2/12

X2/15

Yellow /black

Heater element bypass flap motor – close  Air-conditioning system supplied supplied by Behr (A480) Operate “REHEA “REHEAT” T”  – Operate pushbut pushbutton ton switch switch (de-humidify) (S545) Line colour

X2/12

 

Grey/red

 

  Measured value [V]

~= -16 - 32 V (U bat) REHEAT REHEAT function function deactivated; deactivated; brief  signal

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

~= -16 - 32 V (U bat) REHEAT REHEAT function function activat activated; ed; brief  brief  signal

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

~= 16 - 32 V (Ubat) REHEAT REHEAT function function deactivated; deactivated; brief  signal

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

Grey /red

X2/15

Heater element bypass flap motor – close  Air-conditioning system supplied supplied by Behr (A480) Operate “REHEA “REHEAT” T”  – Operate pushbut pushbutton ton switch switch (de-humidify) (S545) Line colour 

P in +

Desired value [V]

X2/15

Yellow /black

X2/12

 

Grey/red

Yellow /black

Reference Reference voltage Measuring Measuring device

Contr Control ol elemen elementt pin pin designation

Reference voltage 5 V  Air-conditioning system supplied supplied by Behr (A480) Line colour 

 

P in +

Pin-

X2/11

X2/5

Desired value [V]

~= 5 V Black /white

  Measured value [V]

 

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

Red /white

Diagnosis, Diagnosis, K-line Cont Contro roll elem elemen entt designation

pin pin

Diagno Diagnosis sis K-line K-line diagno diagnosti sticc socket (X200) Condition: No   data traf fic on K-line Line number Diagno Diagnosis sis K-line K-line diagno diagnosti sticc socket (X200) With data traf fic on K-line Line number

Measuring Measuring device Pin+

Pin-

X1/9

X1/12

24201

31000

X1/9

X1/12

24201

31000 T 69

Desired value [V]

 

Measured value [V]

16 - 32 V (Ubat - 2 V) (MAN (MAN-c -cat atss II not not connected)

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

0 - 32 V (Ubat - 2 V) (MAN (MAN-c -cat atss II connected)

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

2 - 49

DEVICE DESCRIPTION Deleting the fault memory

No more active faults are allowed to be stored in the fault memory once all tests have been performed and no faults are found! Before deleting the fault memory, download it using MAN-cats II and if it contains any non-diagnosed faults then these must be archived. archived. Then delete the fault memory. memory. There must not be any faults in the memory when the ignition is switched back on. Otherwise, search for the fault and remedy the problem.

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    9     6     T

    M     E     T     S     Y     S     G     N     I     N     O     I     T     I     D     N     O     C       R     I     A     E     H     T     F     O     W     E     I     V     R     E     V     O     F     E     I     R     B

    )    m    e     t    s    m    y    s    e       t    s    m    g   —    y    e     i    n    )     t    s   —    s    m    n    y    g    o    t    e   —    s     i     5    n     t    s     i     i     1    n    g     d    y   —     l    n    n    s    o     i     i    a     t   —    o    g     i    n    n    c     i     d    o    n     —     i    r     i    n    m     t     i     i    n    r    o    a    i   —     d     (    o    m    e    m    c     t    n    R    k    i     t    e      e   —     t    r  ,    o     i     t    s    n    d    c    s    a    m   m    n    y   -     H    a    y     E    r  ,    e     0    e    s   —    o    s     i     i     B    t    r     t     t     0    c     t    a    n   -    g    a    p    s    s    0    g   —    y    r    n    r    a    y    y    a    i    n   —     h    e    s    s    1     t     b    r    a    i    n    o    g         fl     i    r    e     i     3    n   —     i     (    n    n     i    g    g    e    i    r    u    o    r     i    w    d    e    n    o     i     i     t    r     l    o    g    n     t    n     i     i    e    t    a    e    i     t     /     i     i     i     i   -     i     4    a     t     t    n    r    a     l    r    a     i     h     t    p    f     d    n    i     )    n    l     K   r     d   —    r     0    n    g    e    g    r    n    i    n    s    u    p    r    o    o  ,  ,    o    n   —    o    p    e     1     i     t     i     i    n  ,     l     i    p    a     9    i    o    o    m   r     t     i    o    u  ,     i     t    n    s    o   —    s    a    n    i     t     t    r     h     5    s    c    o    m    c     d    d    i    n          fl    i    r     t    s    h    e    c    u    s    n    l    a    p    p       i       l    e    e    .      n       l    n     t    r    e    r    s    a    m    c    n    i    e    e    r     t     i  .   —     i    r    u     t    n    w     N  .     1    s    o     1    o    e    m    i    o    s    g    n    c    c    2    2    p    a     t    e    m   r    c    r    r     A    K    i     t    a    i     l    e    w    i    g    t   -    r  ,     /     i   -  ,  ,    m    t   —    r    s    e    s    o    e    a    i    s    r    u    n     i    r    r    n    r    r  ,  ,    n    c    s    y     i    r    w    (     M    8    r     i    r    r    o    n   —   r    u    n    p    t    s     i    u    e    t    e    e    o    e    e     t     l    s    2    y    a    o    a    y    e    o    o     t    s    b    l    o  ,  ,     t     t    c    f     l    s    /    e    s    w   n    r    a    r    o     t    r    o    a     t     1     t     l    r     l    s    r    a    o    u    i    n    i  ,  ,   —   s    r    r     t    u    r    r     T    i    n    b    e    7    c    n    n    u    u    h    e    e    u    n    o    t    a    t    o    t     l     t    e     A    n    g     b     b    n     k    e    c    c    e    e     h    a  ,    s     t     K     i     i    a  ,  ,    c    n    i    o    i    o    r    r     t     i    e   —   e    p    g    n    c    v    r     N    E    h    r    n    o    b    i    n    s    s    b    r    u    u    r     t     t    n    t    e    i     t     t    p    i     t    e    h    O    H   c    h    o    r     b    e     l    s    o    c    c    n    u    e     t    e    c    c    n   —    c    s    s    e    c    m    t     l    m    a    o    r    r     t    e    h    p    e    s     E    i    a    c     t    s    k    o    e    e    i     i    c    a    r    e    a    m   r     t     i    e     t    e     C     i     d     d    v    u    a    s    m   m   r    p    e     l    o    n  ,     i    c    n    n    l     l    e    /    o    t     h    l   —    e    s    c   -     t    w    i    w   s     t    r    c    e    c    s    t     f     A    R   s    c    i     l    c     i    o    n    n    a    e    u    e     i     d    e     d     d    w   r    s    a    o    a    a     t     t     l     l    e    l   —    x  ,  ,  ,    a     i    s    e    o    o    i    a    n    r    p  ,     i     t     h    h    h    r     t    e    o    r    o    e    h    a    r    y    o    a    m   r    o    n    y    r    n    e    r     l    e    e    c    c    t    o    r  ,  ,    y    r    p    e    o    n     /    n    n    y    n    n   —     h    u    n    p    c    c    c     t     t     t     t     t     t    u    w    p    e    e    r     t     t     t    c    a    a    a    e    g    e    e    s     h    a    g    g    e    e     i     i     i    g    n    n    s    n    r     t     t    a    l     i    m   u    u    t     t    a    l   —   a    t    a    a    e    q    o   -    g    m   s    s    l     t    e    e    n    o    i    e    e     i    e    u    u    e    o    w   w   w   o    o    i    e    r     l     l    o    o    o    v    x    r    e    l     C    C    I     C    A    H    T    F    F    R    P    S    S    S    R    R    D    R    C    P    P    P    P    M    S   —     E    E    H    H    F    S    B     d

   n     0    4    2    3    1    4     1    e     0    2    7    4    0    3    3    7    5    8    6    3    4    5    6    7    0    6    5    2    2    4    4    4    7   –     0     0     0     1     0     0     0     7     8     9     2     4     4     4     4     0     5    7    8    8    5    5    1    1    g     9     2  .     4    e    1    3    4    4    4    2    3    3    1    7    1    1    5    5    5    5    2    1    1    1    1    2    2    1    1   —     0     L    A    A    A    A    A    B    B    F    F    K    R    S    S    S    S    S    X    X    X    X    X    X    X    Y    Y   —     1    2    3    4    5    6    7

    3     5       3

    S     M     A     R     G     A     I     D     G     N     I     R     I     W     L     A     N     O     I     T     I     D     D     A

    9     6     T

    M     E     T     S     Y     S     G     N     I     N     O     I     T     I     D     N     O     C       R     I     A     E     H     T     F     O     W     E     I     V     R     E     V     O     F     E     I     R     B

    4     5       3

    S     M     A     R     G     A     I     D     G     N     I     R     I     W     L     A     N     O     I     T     I     D     D     A

  –

    0     8     3     1  .     2     9     1     9     9  .     1     8  .     O     N     M     A     R     G     A     I     D     G     N     I     R     I     W

    2     f    o     1     t    e    e     h    s    m    a    r    g    a     i     d    g    n     i    r     i    w    m    e     t    s    y    s    g    n     i    n    o     i     t     i     d    n    o    1    c   -     0  .    r     i     4     A    0

   r   —    o    s   —    n    e   —    s   —    e    r   —    m    u   —    e     t     t    a    s    m    r    e    )    y    e   —     t    p   —    s    m    s    y    g    e    m  —    s    t     5    n     i    s    e     1     t   —    n    g    y     l    s    n    o    r     i     i    a     i   —     t    n    n    g     i    a     i     d    o    i    n     l   —     i    n    m     t    n    a     i    r    o   —    n     d    o    m    e    m   c    r     t    n    i     t    e      e     i     t    e    r   —  ,    o     t     d    t     i    c    a    m   m    s    n   —   -    n    s     i    y    r  ,    e    e    0    y    s    o    s    i     i    c    r     t     t  ,   —    a   -    g    a    p    s    s    0    e    g     0    y    r    y    v   —    a    n     i     i     h    r     1     i    n    e     l    s    s     t     i     (    a    n    i    r    o         fl     3    n    a   —    g    g    e    i    r    u    r     i    w    i    o    v     t    r    o    n    n    e    a     t     /    a    i     i     i     i     4    a     t     i     t    n    g   —    r     i     t     d    i    n    l     d     0    n    g    e    n   —    u    r    n    n    o    i    o  ,    n     1    i     i    n  ,     i    p    o    o    r     t    o    i     t     9     i     i     i    n    o     t    m    r   —     h     5    o    m     d    d    p    c     i     t    e    c    a       l     t   —   m     i    s    e    .    n   -     i    n     t    r     t  . .    e    r    n    u    w    i    r     t     i    o     1    o    n    e    n    c    c    2    a    c    r    r     K    i    e   —   s    g  ,     /    a    e    r     t   -    r   -  ,     t    o    e  ,     l ,     i     i    r    r    s    i    n    c    a   —   y    2    i    r    w    8    r    r     i    r    n    o    e    e     t    s    e    a    o    a    e    o    r    o  ,  ,     t    w     l    r    a    s    w   r     /    r    o     t     1     t     l     f    u  ,   —   a    t    n     T    u    r    n    e    c     7    e    o     t     i     b    e    n    n    b  ,    y    c     h    e    l    a    i     l  ,  ,     K   n    i    o    i    o    i    u    s    b    r    a    N    A     i    e    r    v     E    r    p   —     t     t     h     t     h     t    p     t     b    r     O    e     l     h    n    e    e    p    s     H    t    c    c    p   —   c    m   a    r    c    c    s    e     t     k    o    e    e    i    a     i     t    u     l    e    o    c    t     d    v    e    C    E    i    c    n    n    l    a    m    f    s   —    r    w   c    w  ,    u     A     R    e    c    s    o    e    n    n    a    e     d    s    s     d    a    i     l     l     l    r     h    t  ,  ,  ,    e   —    o    c    o    i    e    c     t    o  ,     h    h    h    r    a    r    y    s    a    r    o    e  ,    y    y    r    g   —   r    p    n    n    c    i    c    i    c    a    a    y    a     t     t     t    p    e    a    i     t     t     t    a    e     t    g    g    e     t     t     l    m   u    u    t     l     l   —   n    n    n    m   s    l    r     l     l    o    o    o    e    e    o    e    u    e    w   w   w   o    o    e    i     V   —     C    C    C    T    F    R    S    S    S    R    R    R    C    P    P    P    S     d     0    4    2    3    1    n   –     0    2    4    3    7    8    3    4    5    6    7    6    5    2    2    4    7    e     0    0    7    9    9    1    2    4    4    4    4    5    7    8    8    5    1    g   —     1    3    4    3    3    7    1    5    5    5    5    1    1    1    1    2    1    e     L    A   —     A    A    A    B    F    K    S    S    S    S    S    X    X    X    X    X    Y

    9     6     T

    5     5       3

    S     M     A     R     G     A     I     D     G     N     I     R     I     W     L     A     N     O     I     T     I     D     D     A

    9     6     T

    2     f    o     1     t    e    e     h    s    m    a    r    g    a     i     d    g    n     i    r     i    w    m    e     t    s    y    s    g    n     i    n    o     i     t     i     d    n    o    c      r     i     A

    6     5       3

    S     M     A     R     G     A     I     D     G     N     I     R     I     W     L     A     N     O     I     T     I     D     D     A

    9     6     T

    0     8     3     1  .     2     9     1     9     9  .     1     8  .     O     N     M     A     R     G     A     I     D     G     N     I     R     I     W

    )    m    e     t    s    y    s        m    g   —   —    e     i    n     t   —   —    s    n    y    o   —   —    s     i     5     t     i     1    g     d   —   —     l    n    n     i    a   —   —    o    n    c    n     i    o     —     i    r     R   —     t     i    m     i    r     H   —    a   —     d     (    e     t     E   —    n    R    k   —  ,    o     B     H   n    I     I    m   m    c   —   —      y    a    x    t    r     E    t    e    t    e     i     b   —     B   —    o     t    a    n    b    s    s    y     d   —    y    a    r    y     h    r    e     t     b    r    a    s    s     i    e   —     l   —    o    i    n   —    e    g    g    w    d    e     i    s    p     l    g    g    n    n    e     /     i       i     i     /     0     0     i    s    p   —   —    r     C   n    n    0    0    K     t     l     f    r   —    e    r    u    p    u    r    s   —    o    o    e     0     3    o  ,     i     i    o    p    s    r     D    i     t    o    p     t    p   —     8     8    s    n     i    a    u     i  ,     E     h   —     5     5    s     d    r          fl    n     t    s    h    /     d    m   m    m     i     i    e   —   -    r    n    n    e    e    p    e    c    e    e   —   e    w     i    a    s    r    o    t     t     1    o    o    n    m     i    c    c    i    o    s    n    i    n    2    p    c    s   —    s     t    g     l     l    s   —    e    g   -    r    w   g    r   -  ,  ,  ,    m    r    n    a    n    r  ,    s    n    t    s    e     i    y    n    i     i    p    e    u    r    g   y    s    r    r    r     i    o     t     2    e    s   —   —     t     l    s    y    e    a    a    y    o    n    o    o    t    c     l     l    e  ,  ,  ,     t    s    t    o     i     l    r     b    r     k    l    r    g   —    a    s    o    a  ,   —   r    e    a    c    t    c    u    h    r    e    s    u    a    t    u    n    n     t    n    n   p    i    n    c     t    g     b    n    e    e    c    e    e     h    s     i    o    i    o    i    o    n    n    r     t    a    u   n   —     i    c   —   n     i    r    n    n    s    i    e     t    r    u    g    p    s     i     t     t     t    e     t    p     t     b    o    o    c    n    n    u   —   c    e    m   n    m    e    c    c    c    o    o    i     t    c    i    o   —   c    m   a    n    r    s    l    r    a    o    e    e    e    c    c    d    c   —    n     i     t     l    e    o    c    i    r     l    e    o    e    h    t     t    p    e     /    n    n    a   -    n    c    d   —  ,     i     t     l    r    e    c    c    c    r     i    c     l     i    n    n    n     i    e    s     d     d    a    a    t   —   n    r    a    r    x    a    r    w   o    o    o    e    e    i     l     l     l     d    e    t    n   —    n    e     t    o    c    c    c    p    p    e    e    e    e    e    n    o    a    r    a    r    o    o    l    g   n   o   —    r     /    n   —     h    r     i     t     t     t    c    h    g    g    g     t     t    e    p    r    g   c    e    n    w   s   -   —    g    u    o     f    n    n    n    r    a    a    a    m   m    t   -    g    u    u    u    i    r    e    e    e    o    i    r    o    a   —   q    e    a    i     i     l     l     l    r     i    e    l    r    e    e    t    x    v     R    M    A   —     C    C    C    A    H    P    P    P    C    C    P    M  —     S    B    F    H    H    E    E

    2     f    o     2     t    e    e     h    s    m    a    r    g    a     i     d    g    n     i    r     i    w    m    e     t    s    y    s    g    n     i    n    o     i     t     i     d     d    n     2    3    5    8    4    o    1    n   –    0    2    4    0    3    1    e     5    2    2    3    3    4    4   –    c     0       0     0     0     7     8     5     8    8    8    5   —    g  .   —    r    4     1    3    4    4    2    1    8     i     1    1    1    1    2    1     1    e     A    0     L    A    B    C   —     A    A    A    A    B    X    X    X    X    X    X    Y   —     1    2    3    4    5    6    7

    7     5       3

    S     M     A     R     G     A     I     D     G     N     I     R     I     W     L     A     N     O     I     T     I     D     D     A

    9     6     T

    2     f    o     2     t    e    e     h    s    m    a    r    g    a     i     d    g    n     i    r     i    w    m    e     t    s    y    s    g    n     i    n    o     i     t     i     d    n    o    c      r     i     A