Page 1 of 26

Test step list

Test step list

The test step list enables you to check the vehicle management computer and auxiliary vehicle computer
components or functions using the contact box and a multimeter (e.g. FLUKE 77 or 87).
Test description
In the test step list in this section (example: test step 1), the test contact is designated "Pin X4/8". This
corresponds to the designation "8" (light grey area) on the contact box. The second test contact is
designated "Pin X1/3". This corresponds to the designation "3" (white area) on the contact box.

A diagnosis overlay is placed on the contact box. This diagnosis overlay indicates the vehicle
management computer / auxiliary vehicle computer plug connections:
White area - applies to connector X1
Dark grey area - applies to connector X2
Purple area - applies to connector X3
Light grey area - applies to connector X4
The measuring mode to be set on the measuring device (multimeter) is indicated between the test contacts in
column 2.
Example: Setting “V” = Voltage measurement
Example: Setting “Ω” = Resistance measurement
Once the test requirements have been fulfilled, the value (actual characteristic) indicated on the measuring
device (e.g. FLUKE 77 or 87 multimeter) can be compared with the desired value (desired characteristic).
Two sample measurements are described below:

If voltages are being measured, switch on the ignition and leave the vehicle management computer
connected.
The figure above is a measurement example based on the TGA.
In this example, the voltage supply for vehicle management computer terminal 30 is measured between pin
X1/1 - positive line and X1/3 - ground line.
Items "1" and "3" – each in the white area – are connected on the contact box.
The measured value obtained using the FLUKE 77 multimeter is 24.97V (battery voltage).

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 2 of 26

Switch off the ignition if resistance values are being measured. The contact box is connected between the
vehicle management computer and the vehicle. All the jumpers in the contact box must be closed. The
jumper at which the value is being measured must be open.
The figure above is a measurement example based on the TGA.
In this example with the powertrain CAN databus (T-CAN), the resistance is measured between pin X1/14 (T-
CAN low signal) and X1/15 (T-CAN high signal).
Items "14" and "15" – each in the white area – are connected on the contact box.
The value measured with the FLUKE 77 multimeter is 121.3Ω.

Test step list for vehicle management computer (A403)

Service company: Tested by:
Customer: First registration:
Vehicle type: Chassis number:
Engine model: Engine number:
CR high-pressure pump: Control unit no.:
Mileage (km): Date:

Read out the vehicle management computer fault memory using MAN-cats® II. The test step list is
designed to pinpoint the entered active faults.
Use the vehicle-specific overviews and wiring diagrams for troubleshooting.
When the voltage is measured, the ignition must be switched on, the engine must be running and the
vehicle must be 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
The contact box is connected between the vehicle management computer and the vehicle.
All the jumpers in the contact box must be closed. The jumper at which the value is being measured must
be open.
Digital switch monitoring

Remarks: in active state, the switch is closed.

FFR pin designation Measuring instrument Desired value Measured value [Ω]
Pin+ Pin- [Ω]

External engine stop request X4/8 X1/3 ~= 4.6kΩ ..................

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 3 of 26

TGA: Reverse shift lock

R02/R03/R07/R08: Multiplex
node, front, control units 1.3
(A413)
A37 with TEPS: Switch, engine
start/stop (S176)
Line number 43315 31000
External engine stop request,
terminal 50
TGA; R02/R03/R07/R08:
Steering lock (Q101)
A37 without TEPS: Resistor
bank, potential reduction (R234),
X3/7 X1/3 ~= 4.6kΩ ..................
multiplex node, front, control units
1.3 (A413)
A37 with TEPS: Relay, starter
interlock, gearbox (K315) for EDC
MS6.1; relay for starter control
(K755) for EDC 7 common rail
Line number 50300 31000
Request, intelligent brake function
(linking)
TGA, R02/R03/R07/R08: Switch,
auxiliary brake (S479), switch,
engine brake (S753)
A37 without TEPS: Resistor
X1/16 X1/3 ~= 4.6kΩ ..................
bank, potential reduction (R234),
multiplex node, front, control units
1.3 (A413)
A37 with TEPS: Switch, auxiliary
brake (S479), auxiliary brake
lever (A437)
Line number 60610 31000
Request FGR/FGB (cruise
control/road speed limiter)
TGA, R02/R03/R07/R08: Switch,
X2/16 X1/3 ~= 4.6kΩ ..................
FGR/FGB (S284)
Closed: FGB
Open: FGR
Line number 60521 31000
Request, power take-off 1
TGA: Switch, power take-off 1 X2/14 X1/3 ~= 4.6kΩ ..................
(S222)
Line number 40354 31000
Request, power take-off 2
TGA: Switch, power take-off 2 X2/15 X1/3 ~= 4.6kΩ ..................
(S223)
Line number 40355 31000
Request split
TGA: Switch, gear selector lever
(S477) X1/13 X1/3 ~= 4.6kΩ ..................
Closed: Split Low
Open: Split High
Line number 60606 31000
Request, Comfort Shift 1
TGA: Switch, gear selector lever X2/12 X1/3 ~= 4.6kΩ ..................
(S477)

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 4 of 26

Line number 60632 31000

Request, Comfort Shift 2
(redundant input)
X2/3 X1/3 ~= 4.6kΩ ..................
TGA: Switch, gear selector lever
(S477)
Line number 60665 31000
TGA, R02/R03/R07/R08; A37
with TEPS: Request, X3/2 X1/3 ~= 4.6kΩ ..................
intermediate speed governor 1
Line number 60525 31000
TGA, R02/R03/R07/R08; A37
with TEPS: Request,
intermediate speed governor 2 X3/9 X1/3 ~= 4.6kΩ ..................
A37 without TEPS: Idling speed
increase
Line number 60526 31000
TGA, R02/R03/R07/R08; A37
with TEPS: Request, X3/11 X1/3 ~= 4.6kΩ ..................
intermediate speed governor 3
Line number 60641 31000
Feedback, gearbox neutral
TGA: EATON RTSO, ZF
16S151/16S181 switch, neutral
position (S172) X3/15 X1/3 ~= 7.5kΩ ..................
R07/R08; A37 with TEPS:
G0210-6 Switch, neutral position
(S172)
Line number 60144 31000
Feedback, power take-off 1
TGA: Switch, indicator, power X4/15 X1/3 ~= 7.5kΩ ..................
take-off 1 (S219)
Line number 40141 31000
Feedback, power take-off 2
TGA: Switch, indicator, power X4/12 X1/3 ~= 7.5kΩ ..................
take-off 2 (S220)
Line number 40142 31000
TGA: Request, engine brake
A37 with TEPS: Auxiliary brake X3/1 X1/3 ~= 7.5kΩ ..................
lever (A437)
Line number 43568 31000
Feedback, parking brake
TGA, R02/R03/R07/R08; A37
with TEPS: Switch, check,
parking brake (B369)
X2/2 X1/3 ~= 7.5kΩ ..................
A37 without TEPS: Resistor
bank, potential reduction (R235),
Multiplex node, front, right 2.1
(A421)
Line number 16109 31000

Frequency monitoring

Measuring instrument Desired value [Ω] Measured value [Ω]

FFR pin designation
Pin+ Pin- FFR Vehicle FFR Vehicle

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 5 of 26

Gearbox speed signal, X3/12 X1/3 ~= 1.78kΩ ~= 1.05kΩ ......... .........

inductive pickup
TGA; R07/R08; A37 with
TEPS
Gearbox input speed
(B368)
Line number 60613 31000
Gearbox speed signal,
inductive pickup, ground
TGA; R07/R08; A37 with
X4/17 X1/3 ~= 1.90Ω ~= 2.83kΩ ......... .........
TEPS:
Gearbox input speed
(B368)
Line number 60614 31000
Immobiliser TGA,
R02/R03/R07/R08; A37
with TEPS:
X1/17 X1/3
ECU, immobiliser (A477)
Not available ~= 2.98kΩ ~= 15MΩ ......... .........
Available ~= 13MΩ ~= 20MΩ ......... .........
Line number 99125 31000
Vehicle speed signal /
ECO-Power
A37 without TEPS:
X2/13 X1/3
Tachograph (P100)
Peripherals not wired ~= 585kΩ Infinite ......... .........
Peripherals wired ~= 36.4kΩ ~= 1.3MΩ ......... .........
Line number 16503 31000

Serial control switches

Measuring instrument Desired value [Ω] Measured value [Ω]

FFR pin designation
Pin+ Pin- FFR Vehicle FFR Vehicle
Preselector switch, data
line TGA,
R02/R03/R07/R08; A37
with TEPS: Mode switch,
gearbox (A434) (AS-
X2/7 X1/3
Tronic)
A37 without TEPS: Gear
selector switch (S259)
Switch not fitted ~= 1.5MΩ Infinite ......... .........
Switch fitted ~= 5MΩ ~= 5.5MΩ ......... .........
Line number 60616 31000
Preselector switch, clock
line TGA,
R02/R03/R07/R08; A37
with TEPS: Mode switch,
gearbox (A434) (AS-
X1/8 X1/3
Tronic)
A37 without TEPS: Gear
selector switch (S259)
Switch not fitted ~= 1.7MΩ Infinite ......... .........
Switch fitted ~= 6.1MΩ ~= 3.7MΩ ......... .........
Line number 60615 31000

Retarder data line X2/10 X1/3 ~= 1.5MΩ ~= 1.6MΩ ......... .........

TGA, R02/R03/R07/R08;

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 6 of 26

A37 with TEPS: Auxiliary

brake lever (A437)
Line number 43554 31000
Retarder clock line
TGA, R02/R03/R07/R08;
X1/6 X1/3 ~= 1.7MΩ ~= 1.2MΩ ......... .........
A37 with TEPS: Auxiliary
brake lever (A437)
Line number 43553 31000
Gearbox FGR and
retarder data line
TGA, R02/R03/R07/R08;
X2/8 X1/3 ~= 1.5MΩ ~= 1.6MΩ ......... .........
A37 with TEPS: Steering
column stalk, cruise
control / gearbox (A429)
Line number 60607 31000
Gearbox FGR and
retarder clock line
TGA, R02/R03/R07/R08;
X1/7 X1/3 ~= 1.2MΩ ~= 1.7MΩ ......... .........
A37 with TEPS: Steering
column stalk, cruise
control / gearbox (A429)
Line number 60608 31000

Analogue monitoring

Measuring instrument Desired value [Ω] Measured value [Ω]

FFR pin designation
Pin+ Pin- FFR Vehicle FFR Vehicle
Multi-stage switch, max.
road speed limiter
X2/6 X1/3 ~= 6.5kΩ ~= 510Ω ......... .........
Resistor bank, EDC
(R134)
Line number 60523 31000
Multi-stage switch,
torque limiting
X2/1 X1/3 ~= 6.5kΩ ~= 510Ω ......... .........
Resistor bank, EDC
(R134)
Line number 60524 31000
Ground, multi-stage
switch, max. road speed
X1/4 X1/3 ~= 2.1Ω ~= 4.5kΩ ......... .........
limiter, eng. speed
range, AGD
Line number 31016 31000
Outside temperature,
outside air temperature X3/14 X1/3 ~= 10kΩ ~= 2.38kΩ ......... .........
sensor (B269)
Line number 60147 31000
Ground, outside
temperature, outside air
X4/18 X1/3 ~= 1.8Ω ~= 12.3kΩ ......... .........
temperature sensor
(B269)
Line number 31017 31000
TGA: Oil probe, hot wire
X2/4 X1/3 ~= 9kΩ ~= 6.6Ω ......... .........
sensor, signal
Line number 16129 31000

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 7 of 26

TGA: Oil temperature

sensor (oil temperature- X3/3 X1/3 ~= 5.6kΩ ~= 2.3kΩ ......... .........
dependent)
Line number 16138 31000
TGA: Ground, oil level
X4/5 X1/3 ~= 0.4Ω ~= 4.36kΩ ......... .........
measurement
Line number 31027 31000
Request, group change
TGA: Switch, gear
selector lever (S477) X3/8 X1/3
Switch closed ~= 660kΩ ~= 1.16kΩ ......... .........
Switch open ~= 660kΩ ~= 5kΩ ......... .........
Line number 60634 31000

Clutch travel monitoring

Measuring instrument Desired value [Ω] Measured value [Ω]

FFR pin designation
Pin+ Pin- FFR Vehicle FFR Vehicle
Clutch travel sensor,
signal acquisition
TGA; R07/R08; A37
X4/9 X1/3 ~= 9.3kΩ ~= 1.2MΩ ......... .........
with TEPS:
Clutch travel sensor
(B362)
Line number 60142 31000
Ground, clutch travel
sensor
TGA; R07/R08; A37
X4/3 X1/3 ~= 1.2MΩ ~= 9.4kΩ ......... .........
with TEPS:
Clutch travel sensor
(B362)
Line number 60143 31000

Exhaust gas backpressure monitoring

Measuring instrument Desired value [Ω] Measured value [Ω]

FFR pin designation
Pin+ Pin- FFR Vehicle FFR Vehicle
5V supply, exhaust gas
backpressure sensor /
brake pedal sensor X2/5 X1/3 ~= 100kΩ ~= 3.7kΩ ......... .........
TGA: EVB module
(Y355)
Line number 43012 31000
Signal, exhaust gas
backpressure
X3/4 X1/3 ~= 100kΩ ~= 12.2kΩ ......... .........
TGA: EVB module
(Y355)
Line number / colour blue 31000
Ground, exhaust gas
backpressure sensor /
brake pedal sensor X1/5 X1/3 ~= 1.9Ω ~= 54kΩ ......... .........
TGA: EVB module
(Y355)
Line number / colour brown 31000

CAN databus

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 8 of 26

Measuring instrument Desired value Measured value

FFR pin designation
Pin+ Pin- [Ω] [Ω]
Resistance betw. T-CAN
High and T-CAN Low
X1/14 X1/15
FFR disconnected approx. 120Ω ..................
FFR connected approx. 60Ω ..................
Line colour Blue/red Blue/white
Resistance betw. M-CAN
High and M-CAN Low
X1/10 X1/12
FFR disconnected approx. 120Ω ..................
FFR connected approx. 60Ω ..................
Line colour Black/green Green/black

Output stage, terminal 15 and terminal 30

Measuring instrument Desired value [Ω] Measured value [Ω]

FFR pin designation
Pin+ Pin- FFR Vehicle FFR Vehicle
Warning light, FFR and
EDC fault
A37 without TEPS:
Resistor bank, potential
reduction (R234), X2/9 X1/3
multiplex node, front,
control units 1.3 (A413) Infinite
Warning lamp not fitted ~= 2.17MΩ ~= 29kΩ ......... .........
Warning lamp fitted ~= 3MΩ (ZBRO) ......... .........
Line number 60107 31000

Output stage, terminal 30

Measuring instrument Desired value [Ω] Measured value [Ω]

FFR pin designation
Pin+ Pin- FFR Vehicle FFR Vehicle
Engine brake
TGA, R02/R03/R07/R08;
A37 with TEPS: Solenoid
valve, engine brake X4/14 X1/3 ~= 8.82kΩ ~= 22Ω ......... .........
(Y281)
TGA: EVB module
(Y355)
Line number 43301 31000
Fan clutch
TGA: Solenoid valve, fan
clutch (Y273)
A37 with TEPS; A37
X4/16 X1/3 ~= 8.87kΩ ~= 25Ω ......... .........
without TEPS;
R02/R03/R07/R08:
Control valve, fan drive
(Y144)
Line number 61304 31000
FGB check lamp
TGA, R02/R03/R07/R08;
A37 with TEPS: Steering X2/17 X1/3 ~= 8.4kΩ ~= 1.67kΩ ......... .........
column stalk, cruise
control / gearbox (A429)
Line number 60609 31000
Power take-off 1

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 9 of 26

TGA: Solenoid valve,

power take-off 1 (Y153)
Power take-off 1 not fitted X4/2 X1/3
~= 4.3kΩ Infinite ......... .........
Power take-off 1 fitted ~= 4.5kΩ ~= 60Ω ......... .........
Line number 40329 31000
Power take-off 2
TGA: Solenoid valve,
power take-off 2 (Y154)
X4/11 X1/3
Power take-off 2 not fitted
~= 4.4kΩ Infinite ......... .........
Power take-off 2 fitted ~= 4.5kΩ ~= 60Ω ......... .........
Line number 40330 31000
Thermostat valve, heating

TGA, R02/R03/R07/R08:
Thermostat for heating 1 X4/4 X1/3
(R173)
Heating thermostat valve
not fitted ~= 4.3kΩ Infinite ......... .........
Line number 60355 31000
Low group
TGA: Solenoid valve,
X3/10 X3/5 ~= 6kΩ ~= 85Ω ......... .........
range-change group,
EATON RTSO (Y312)
Line number 60370 31025
Solenoid valve, splitter
and range-change, ZF
X3/10 X1/3 ~= 4.2kΩ ..... ......... .....
16S151 / ZF 16S181
(Y307)
Line number 60370 31000
High group
TGA: Solenoid valve,
X4/1 X3/5 ~= 6.28kΩ ~= 84.3Ω ......... .........
range-change group,
EATON RTSO (Y312)
Line number 60371 31025
Solenoid valve, splitter
and range-change, ZF
X4/1 X1/3 ~= 4.3kΩ ..... ......... .....
16S151 / ZF 16S181
(Y307)
Line number 60371 31000
Shift lock
TGA: Solenoid valve,
X4/13 X3/5 ~= 8.9kΩ ~= 135Ω ......... .........
range-change group,
EATON RTSO (Y312)
Line number 60372 31025
Solenoid valve, splitter
and range-change, ZF
X4/13 X1/3 ~= 8.3kΩ ..... ......... .....
16S151 / ZF 16S181
(Y307)
Line number 60372 31000

Ground shut-off
TGA: Solenoid valve, X3/5 X1/3 ~= 11kΩ ..... ......... .....
range-change group,
EATON RTSO (Y312) /

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 10 of 26

Solenoid valve, splitter

and range-change group,
ZF 16S151 / ZF 16S181
(Y307)
Line number 31025 31000
High split position
TGA: Solenoid valve,
X3/13 X4/6 ~= 6kΩ ~= 83.3Ω ......... .........
range-change group,
EATON RTSO (Y313)
Line number 60354 31023
Solenoid valve, splitter
and range-change, ZF
X3/13 X1/3 ~= 4.3kΩ ..... ......... .....
16S151 / ZF 16S181
(Y307)
Line number 60354 31000
Low split position
TGA: Solenoid valve,
X4/7 X4/6 ~= 6kΩ ~= 84.6Ω ......... .........
splitter group, EATON
RTSO (Y313)
Line number 60353 31023
Solenoid valve, splitter
and range-change, ZF
X4/7 X1/3 ~= 4.3kΩ ..... ......... .....
16S151 / ZF 16S181
(Y307)
Line number 60353 31000
Clutch servo X4/10 X4/6 ~= 9.6kΩ ~= 47.4Ω ......... .........
Line number 60633 31023
TGA: Clutch servo
X4/10 X1/3 ~= 8.8kΩ ..... ......... .....
(Y308)
Line number 60633 31000
Ground, split
TGA: Solenoid valve,
splitter group, EATON
RTSO (Y313) / Solenoid
valve, splitter and range- X4/6 X1/3 ~= 11kΩ ..... ......... .....
change group, ZF
16S151 / ZF 16S181
(Y307) / Clutch servo
(Y308)
Line number 31023 31000

Voltage measurement
Ignition ON
The contact box is connected between the vehicle management computer and the vehicle.
All the jumpers in the contact box must be closed. Measurement sequences for "Serial control switches",
switches", "Accelerator pedal monitoring", "Immobiliser" and "Diagnosis" are also carried out with the
jumper open.
Voltage is measured with the engine running and the vehicle stationary.

The operating voltage is approximately 28 V, the operating voltage range is 16 - 32 V. The current
consumption is < 1.17A for super-high signals, approximately 0.9A for energised fan clutch and without
power take-offs. The current consumed by the vehicle management computer, not including consumers, is
less than 0.5A.

Supply voltage

Remarks: Pin X1/3 is connected to terminal 31 - battery ground.

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 11 of 26

Measuring instrument Measured

FFR pin designation Desired value [V]
Pin+ Pin- value [V]
Voltage supply, vehicle
management computer - X1/1 X1/3 16 - 32V (Ubat) ..........
terminal 30
Line number 60027 31000
Voltage supply, vehicle
management computer - X1/2 X1/3 16 - 32V (Ubat) ..........
terminal 15
Line number 60044 31000

Digital switch monitoring

Measuring instrument Desired value [V] Measured value [V]

FFR pin
designation Switch Switch Switch Switch
Pin+ Pin-
open closed open closed
External engine stop
request
TGA: Reverse shift
lock
R02/R03/R07/R08:
Multiplex node, front, X4/8 X1/3 16 - 32V
0V .......... ..........
control units 1.3 (Ubat)
(A413)
A37 with TEPS:
Switch, engine
start/stop (S176)
Line number 43315 31000
External engine start
request, terminal 50
TGA,
R02/R03/R07/R08:
Steering lock (Q101)
A37 without TEPS:
Resistor bank,
potential reduction
(R234), multiplex
node, front, control X3/7 X1/3 16 - 32V
0V .......... ..........
units 1.3 (A413) (Ubat)
A37 with TEPS:
Relay, starter
interlock, gearbox
(K315) for EDC
MS6.1; relay for
starter control (K755)
for EDC 7 common
rail
Line number 50300 31000
Request, intelligent
brake function
(linking)
TGA,
R02/R03/R07/R08: X1/16 X1/3 0V Uterm.15 .......... ..........
Switch, auxiliary
brake (S479), switch,
engine brake (S753)
A37 without TEPS:
Resistor bank,

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 12 of 26

potential reduction
(R234), multiplex
node, front, control
units 1.3 (A413)
A37 with TEPS:
Switch, auxiliary
brake (S479),
auxiliary brake lever
(A437)
Line number 60610 31000
Request FGR/FGB
(cruise control/speed
limiter) TGA,
R02/R03/R07/R08:
X2/16 X1/3 0V Uterm.15 .......... ..........
Switch, FGR/FGB
(S284)
Closed: FGB
Open: FGR
Line number 60521 31000
Request, power take-
off 1
X2/14 X1/3 0V Uterm.15 .......... ..........
TGA: Switch, power
take-off 1 (S222)
Line number 40354 31000
Request, power take-
off 2
X2/15 X1/3 0V Uterm.15 .......... ..........
TGA: Switch, power
take-off 2 (S223)
Line number 40355 31000
Request split
TGA: Switch, gear
selector lever (S477) X1/13 X1/3 0V Uterm.15 .......... ..........
Closed: Split Low
Open: Split High
Line number 60606 31000
Request, Comfort
Shift 1
X2/12 X1/3 0V Uterm.15 .......... ..........
TGA: Switch, gear
selector lever (S477)
Line number 60632 31000
Request, Comfort
Shift 2 (redundant
input) X2/3 X1/3 0V Uterm.15 .......... ..........
TGA: Switch, gear
selector lever (S477)
Line number 60665 31000
TGA,
R02/R03/R07/R08;
A37 with TEPS:
X3/2 X1/3 0V Uterm.15 .......... ..........
Request,
intermediate speed
governor 1
Line number 60525 31000
TGA,
R02/R03/R07/R08;
A37 with TEPS:

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 13 of 26

Request,
intermediate speed
governor 2 X3/9 X1/3 0V Uterm.15 .......... ..........
A37 without TEPS:
Idling speed increase
Line number 60526 31000
TGA,
R02/R03/R07/R08;
A37 with TEPS:
X3/11 X1/3 0V Uterm.15 .......... ..........
Request,
intermediate speed
governor 3
Line number 60641 31000
Feedback, gearbox
neutral
TGA: EATON RTSO,
ZF 16S151/16S181
neutral position
X3/15 X1/3 > 26V 0V .......... ..........
switch (S172)
R07/R08; A37 with
TEPS: G0210-6
Switch, neutral
position (S172)
Line number 60144 31000
Feedback, power
take-off 1
TGA: Switch, X4/15 X1/3 > 26V 0V .......... ..........
indicator, power take-
off 1 (S219)
Line number 40141 31000
Feedback, power
take-off 2
TGA: Switch, X4/12 X1/3 > 26V 0V .......... ..........
indicator, power take-
off 2 (S220)
Line number 40142 31000
Request, engine
brake
A37 with TEPS: X3/1 X1/3 > 26V 0V .......... ..........
Auxiliary brake lever
(A437)
Line number 43568 31000
Feedback, parking
brake
TGA,
R02/R03/R07/R08;
A37 with TEPS:
Switch, check,
parking brake (B369) X2/2 X1/3 > 26V 0V .......... ..........
A37 without TEPS:
Resistor bank,
potential reduction
(R235), Multiplex
node, front, right 2.1
(A421)
Line number 16109 31000

Frequency monitoring, gearbox speed signal, inductive pickup

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 14 of 26

Measuring instrument Measured

FFR pin designation Desired value [V]
Pin+ Pin- value [V]
Gearbox speed signal,
inductive pickup TGA;
R07/R08; A37 with TEPS: X3/12 X1/3 ~= 1.6V
..........
Gearbox input speed Alternating voltage
(B368)
Line number 60613 31000
Ground, gearbox speed
signal, inductive pickup
TGA; R07/R08; A37 with X4/17 X1/3 ~= 0V ..........
TEPS: Gearbox input
speed (B368)
Line number 60614 31000

Check with an oscilloscope or Scopemeter 123 made by FLUKE

Measurement taken between pin X4/17 (signal) and X3/12 (ground) - inductive pickup, gearbox input speed
(B368).

Frequency monitoring, vehicle speed signal / ECO-Power

Measuring instrument Measured

FFR pin designation Desired value [V]
Pin+ Pin- value [V]
Speed signal / ECO-Power
A37 without TEPS:
Tachograph (P100)
X2/13 X1/3
~= 9.7V
Peripherals not wired ..........
on FFR side
Peripherals wired ~= 308mV ..........
Line number 16503 31000

Frequency monitoring, immobiliser

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 15 of 26

Measuring instrument Measured

FFR pin designation Desired value [V]
Pin+ Pin- value [V]
Immobiliser TGA,
R02/R03/R07/R08; A37
with TEPS: ECU,
immobiliser (A477)
Immobiliser not fitted;
0V ..........
jumper open: FFR
Immobiliser not fitted;
~= 24.4V ..........
jumper open: Vehicle
X1/17 X1/3
Immobiliser not fitted;
~= 9.6V ..........
jumper closed
Immobiliser fitted; jumper
0V ..........
open: FFR
Immobiliser fitted; jumper
~= 20.6V ..........
open: Vehicle
Immobiliser fitted; jumper
closed ~= 20.7V ..........

Line number 99125 31000

Check with an oscilloscope or Scopemeter 123 made by FLUKE

Measurement is taken between pin X1/17 (data signal) and pin X1/3 (ground) - immobiliser (A477).

Serial control switch - mode switch, gearbox (A434)

Measuring instrument Desired value [V] Measured value [V]

Jumper
FFR pin designation
Pin+ Pin- Open Open
Closed Closed
FFR Vehicle FFR Vehicle

Preselector switch, data

line
TGA, R02/R03/R07/R08;

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 16 of 26

A37 with TEPS: Mode

switch, gearbox (A434)
(AS-Tronic)
A37 without TEPS:
X2/7 X1/3
Gear selector switch ~= ---
(S259) 23.4V 0V ---
Switch not fitted ~= ~= ~= .......... ..........
Switch fitted 21.3V 14.2V 14.2V .......... .......... ..........
Line number 60616 31000
Preselector switch, clock
line
TGA, R02/R03/R07/R08;
A37 with TEPS: Mode
switch, gearbox (A434)
(AS-Tronic) X1/8 X1/3
A37 without TEPS:
Gear selector switch ~= ---
(S259) 23.4V 0V ---
Switch not fitted ~= ~= ~= .......... ..........
Switch fitted 13.4V 22.2V 12.2V .......... .......... ..........
Line number 60615 31000

Check with an oscilloscope or Scopemeter 123 made by FLUKE

The clock signal can be seen on channel A. Measurement is taken between pin X1/8 (clock signal) and pin
X1/3 (ground).

The data signal can be seen on channel B. Measurement is taken between pin X2/7 (data signal) and pin
X1/3 (ground).

Serial control switch - steering column stalk, cruise control / gearbox (A429)

Measuring instrument Desired value [V] Measured value [V]

Jumper
FFR pin designation
Pin+ Pin- Open Open
Closed Closed
FFR Vehicle FFR Vehicle

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 17 of 26

Gearbox FGR and

retarder data line
TGA,
R02/R03/R07/R08; A37 X2/8 X1/3 ~= ~= ~=
.......... .......... ..........
with TEPS: Steering 23.5V 14.2V 14.2V
column stalk, cruise
control / gearbox (A429)
Line number 60607 31000
Gearbox FGR and
retarder clock line
TGA,
R02/R03/R07/R08; A37 X1/7 X1/3 ~= ~= ~=
.......... .......... ..........
with TEPS: Steering 13.5V 22.4V 12.3V
column stalk, cruise
control / gearbox (A429)
Line number 60608 31000

Check with an oscilloscope or Scopemeter 123 made by FLUKE

The clock signal can be seen on channel A. Measurement is taken between pin X1/7 (clock signal) and pin
X1/3 (ground).

The data signal can be seen on channel B. Measurement is taken between pin X2/8 (data signal) and pin
X1/3 (ground).

Serial control switch - auxiliary brake lever (A437)

Measuring instrument Desired value [V] Measured value [V]

Jumper
FFR pin designation
Pin+ Pin- Open Open
Closed Closed
FFR Vehicle FFR Vehicle

Retarder data line

TGA, R02/R03/R07/R08; X2/10 X1/3 ~= ~=
~= 14V .......... .......... ..........
A37 with TEPS: 23.5V 14.18V
Auxiliary brake lever

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 18 of 26

(A437)
Line number 43554 31000
Retarder clock line
TGA, R02/R03/R07/R08;
A37 with TEPS: X1/6 X1/3 ~= ~= ~=
.......... .......... ..........
Auxiliary brake lever 13.5V 22.5V 12.3V
(A437)
Line number 43553 31000

Analogue monitoring

Measuring instrument
FFR pin designation Desired value [V] Measured value [V]
Pin+ Pin-
Multi-stage switch, max.
road speed limiter
X2/6 X1/3 ~= 460mV ..........
Resistor bank, EDC
(R134)
Line number 31000
Multi-stage switch, torque
limiting
X2/1 X1/3 ~= 460mV ..........
Resistor bank, EDC
(R134)
Line number 60524 31000
Ground, multi-stage
switch, max. road speed
X1/4 X1/3 ~= 6.5mV ..........
limiter, eng. speed range,
AGD
Line number 31016 31000
Outside temperature ~= 1.04V
Temperature sensor, X3/14 X1/3 at an outside temperature ..........
outside air (B269) of 22.5°C
Line number 60147 31000
Ground, outside
temperature
X4/18 X1/3 0V ..........
Temperature sensor,
outside air (B269)
Line number 31017 31000
TGA: Oil probe, hot wire
X2/4 X1/3 0V ..........
sensor, signal
Line number 16129 31000

TGA: Oil temperature ~= 1.93V

X3/3 X1/3 Oil temperature- ..........
sensor
dependent
Line number 16138 31000
TGA: Oil temperature
X4/5 X1/3 0V ..........
sensor
Line number 31027 31000
Request, group change
TGA: Switch, gear
selector lever (S477) X3/8 X1/3
Switch closed Uterm.15 ..........
Switch open ~= 23.5V ..........
Line number 60634 31000

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 19 of 26

Accelerator pedal monitoring

Measuring instrument Desired value [V] Measured value [V]

FFR pin Jumper
designation Pin+ Pin- Open Open
Closed Closed
FFR Vehicle FFR Vehicle
Pedal unit, 1st input
Low signal:
TGA, approx. 8V
R02/R03/R07/R08; (accelerator
A37 with TEPS: ~= pedal in end ..........
X2/11 X1/3 ~= 0.5V .......... ..........
Accelerator pedal 25.4V stop ..........
unit (A410) position)
A37 with TEPS: High signal:
Pedal value sensor approx. 20V
(B127)
Line number 60145 31000
Pedal unit, 2nd
input Low signal:
TGA, approx. 8V
R02/R03/R07/R08; High signal:
A37 with TEPS: ~= approx. 20V ........
X2/18 X1/3 ~= 0V ........ ........
Accelerator pedal 25.5V (accelerator ........
unit (A410) pedal in end
A37 with TEPS: stop
Pedal value sensor position)
(B127)
Line number 60146 31000

Clutch travel monitoring

Measuring instrument Desired value Measured value

FFR pin designation
Pin+ Pin- [V] [V]
Clutch travel sensor, signal
acquisition
TGA; R07/R08; A37 with X4/9 X1/3 ~= 2.7V ..........
TEPS: Clutch travel sensor
(B362)
Line number 60142 31000
Ground, clutch travel sensor
TGA; R07/R08; A37 with
X4/3 X1/3 ~= 1.8V ..........
TEPS: Clutch travel sensor
(B362)
Line number 60143 31000

Exhaust gas backpressure monitoring

Measuring instrument Desired Measured

FFR pin designation Remarks
Pin+ Pin- value [V] value [V]
5V supply, exhaust gas
backpressure sensor /
X2/5 X1/3 ~= 5.14V ..........
brake pedal sensor max. current-
TGA: EVB module (Y355) carrying capacity:
Line number 43012 31000 13mA
Input resistance:
Signal, exhaust gas X3/4 X1/3 ~= 564mV .......... 100kΩ after
backpressure terminal 31

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 20 of 26

TGA: EVB module (Y355) Time constant for

Line number / colour Blue 31000 input filter circuit:
4msec
Ground, exhaust gas Protected against
backpressure sensor / overload by PTC
X1/5 X1/3 0V ..........
brake pedal sensor
TGA: EVB module (Y355)
Line number / colour Brown 31000

CAN databus

Measuring instrument Desired value Measured value

FFR pin designation
Pin+ Pin- [V] [V]

Voltage between T-CAN High ~= 1.8 - 3.2V

X1/14 X1/3 Rectangular ..........
and ground
signal*
Line number / colour Blue/red 31000

Voltage between T-CAN Low ~= 1.8 - 3.2V

X1/15 X1/3 Rectangular ..........
and ground
signal*
Line number / colour Blue/white 31000

Voltage between M-CAN High ~= 1.8 - 3.2V

X1/10 X1/3 Rectangular
and ground ..........
signal*
Line number / colour Black/green 31000

Voltage between M-CAN Low ~= 1.8 - 3.2V

X1/12 X1/3 Rectangular ..........
and ground
signal*
Line number / colour Green/black 31000

* check with an oscilloscope or multimeter (Scopemeter) 123 (FLUKE)

The diagram shows signal characteristics for the CAN data bus High signal (channel A) and the CAN data
bus Low signal (channel B).

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 21 of 26

Output stage, terminal 15 and terminal 30

Measuring instrument Desired Measured

FFR pin designation Remarks
Pin+ Pin- value [V] value [V]
Nominal voltage:
Warning light, FFR and ~= 12.75V 24V
EDC fault Warning Saturation
A37 without TEPS: lamp not voltage: < 0.3V
Resistor bank, potential X2/9 X1/3 ..........
fitted at 0.5A
reduction (R234), multiplex ..........
~= 24V Nominal power:
node, front, control units Warning 3W
1.3 (A413) lamp fitted max. nominal
current: 0.5A
Line number 60107 31000

Output stages, terminal 30

The following operating states are valid for the "fan clutch" output stage:

High signal: up to 1.5A at a voltage of 20 - 36V

Low signal: <=1mA at a voltage of approx. 0V
PWM frequency: 50Hz / 1Hz
The following operating states are valid for the other output stages:

Nominal voltage: 24V

Operating voltage 16 - 30V at an ambient temperature of approx. 20°C
Nominal current: 0.4A
Nominal power: 9.6W
Measured
Measuring instrument Desired value [V]
FFR pin designation value [V]
Pin+ Pin- ON OFF ON OFF
Engine brake
TGA, R02/R03/R07/R08;
A37 with TEPS: Solenoid X4/14 X1/3 --- 0V --- ........
valve, engine brake (Y281)
TGA: EVB module (Y355)
Line number 43301 31000
Fan clutch
TGA: Solenoid valve, fan
clutch (Y273)
A37 with TEPS; A37 X4/16 X1/3 ~= 27V 0V ........ ........
without TEPS;
R02/R03/R07/R08: Control
valve, fan drive (Y144)
Line number 61304 31000
FGB check lamp
TGA, R02/R03/R07/R08;
A37 with TEPS: Steering X2/17 X1/3 ~= 27V 0V ........ ........
column stalk, cruise control /
gearbox (A429)
Line number 60609 31000
Power take-off 1TGA:
Solenoid valve, power take-
off 1 (Y153) X4/2 X1/3
Power take-off 1 not fitted ~= 17.3V ~= 17.3V ........ ........
Power take-off 1 fitted UBat 250mV ........ ........
Line number 40329 31000

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 22 of 26

Power take-off 2TGA:

Solenoid valve, power take-
off 2 (Y154) X4/11 X1/3
Power take-off 2 not fitted ~= 17.8V ~= 17.8V ........ ........
Power take-off 2 fitted UBat 250mV ........ ........
Line number 40330 31000
Thermostat valve, heating
TGA, R02/R03/R07/R08:
Thermostat for heating 1
X4/4 X1/3
(R173)
Heating thermostat valve
not fitted ~= 17.8V --- ........ ---
Line number 60355 31000
Low group TGA: Solenoid
valve, range-change group, ~= 27.5V
EATON RTSO (Y312) / For single
X3/10 X3/5 0V ........ ........
Solenoid valve, splitter and High signal
range-change group, ZF every 6 sec.
16S151 / ZF 16S181 (Y307)
Line number 60370 31000
High group TGA: Solenoid
valve, range-change group, ~= 27.5V
EATON RTSO (Y312) / For single
X4/1 X3/5 0V ........ ........
Solenoid valve, splitter and High signal
range-change group, ZF every 6 sec.
16S151 / ZF 16S181 (Y307)
Line number 60371 31000
Shift lock
TGA: Solenoid valve, shift ~= 27.5V
lock, EATON RTSO (Y337) / For single
X4/13 X3/5 0V ........ ........
Solenoid valve, splitter and High signal
range-change group, ZF every 6 sec.
16S151 / ZF 16S181 (Y307)
Line number 60372 31000
Ground shut-off
TGA: Solenoid valve, range-
change group, EATON
RTSO (Y312) / Solenoid X3/5 X1/3 ~= 16V --- ........ ---
valve, splitter and range-
change group, ZF 16S151 /
ZF 16S181 (Y307)
Line number 31025 31000
High split position TGA:
Solenoid valve, splitter
group, EATON RTSO
(Y313) / Solenoid valve, X3/13 X4/6 ~= 27.6V 0V ........ ........
splitter and range-change
group, ZF 16S151 / ZF
16S181 (Y307)
Line number 60354 31000
Low split position TGA:
Solenoid valve, splitter
group, EATON RTSO
(Y313) / Solenoid valve, X4/7 X4/6 ~= 27.6V 0V ........ ........
splitter and range-change
group, ZF 16S151 / ZF
16S181 (Y307)

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 23 of 26

Line number 60353 31000

Measure-
Clutch servo ment not
X4/10 X4/6 possible 0V ........ ........
TGA: Clutch servo (Y308)
when vehicle
stationary
Line number 60633 31000
Ground, split
TGA: Solenoid valve, splitter
group, EATON RTSO
(Y313) / Solenoid valve,
X4/6 X1/3 ~= 16V --- ........ ---
splitter and range-change
group, ZF 16S151 / ZF
16S181 (Y307) /Clutch servo
(Y308)
Line number 31023 31000

Diagnosis K-line

Measuring instrument Desired value [V] Measured value [V]

FFR pin Jumper
designation Pin+ Pin- Open Open
Closed Closed
FFR Vehicle FFR Vehicle

Voltage supply, K-
line, diagnosis
TGA;
R02/R03/R07/R08;
A37 with TEPS; ~= ~= ~=
.......... .......... ..........
A37 without TEPS: X1/18 X1/3 14.7V 22.4V 22.4V
Diagnosis socket
(X200)
Saturation voltage of
K-line driver: <=20%
UBat
Input voltage Low: < 30%
UBat
..........
Input voltage High: > 70%
..........
Line number 60204 31000 UBat
..........
FFR diagnosis, K-line
connected: 0V
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. Then delete the fault 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.

Test step list, auxiliary vehicle computer (A688)

Service company: Tested by:
Customer: First registration:
Vehicle type: Chassis number:
Engine model: Engine number:

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 24 of 26

CR high-pressure pump: Control unit no.:

Mileage (km): Date:

Read out the fault memory of the auxiliary vehicle computer installed in TGA heavy-duty tractors using MAN-
cats® II. The test step list is designed to pinpoint the entered active faults.

Use the vehicle-specific overviews and wiring diagrams for troubleshooting.

When the voltage is measured, the ignition must be switched on, the engine must be running and the
vehicle must be 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
The contact box is connected between the auxiliary vehicle computer and the vehicle.
All the jumpers in the contact box must be closed. The jumper at which the value is being measured must
be open.
CAN databus

Measuring instrument Measured value

FFR pin designation Desired value [Ω]
Pin+ Pin- [Ω]
Resistance betw. T-CAN High
and T-CAN Low
X1/14 X1/15
ZFR disconnected approx. 120Ω ..................
ZFR connected approx. 60Ω ..................
Line colour Blue/red Blue/white

Voltage measurement
Ignition "ON"
The contact box is connected between the auxiliary vehicle computer and the vehicle.
All the jumpers in the contact box must be closed. "Diagnosis" measurements are also taken with the
jumper open.
Voltage is measured with the engine running and the vehicle stationary.
The operating voltage is approximately 28 V, the operating voltage range is 16 - 32 V. Current
consumption < 1.17A for Super-High signal. The current consumed by the auxiliary vehicle computer, not
including consumers, is less than 0.5A.
Supply voltage

Remarks: Pin X1/3 is connected to terminal 31 - battery ground.

Measuring instrument
FFR pin designation Desired value [V] Measured value [V]
Pin+ Pin-
Voltage supply, auxiliary vehicle X1/1 X1/3 16 - 32V (Ubat) ..................
computer
Terminal 30
Line number 60048 31348
Voltage supply, auxiliary vehicle X1/2 X1/3 16 - 32V (Ubat) ..................
computer
Terminal 15
Line number 60049 31348

Main fan - Linnig clutch

Measuring instrument
FFR pin designation Desired value [V] Measured value [V]
Pin+ Pin-

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 25 of 26

Linnig clutch X4/4 X1/3 0V, main fan running ..................

Magnetic clutch, fan (Y273) - 16 - 32V (Ubat), main ..................
via relay, fan clutch (K760) fan not running
Line number 61303 31348

Auxiliary compressor

Measuring instrument
FFR pin designation Desired value [V] Measured value [V]
Pin+ Pin-
Auxiliary compressor request X2/15 X1/3 0V, no compressor ..................
Pressure switch 2, central request ..................
hydraulic system (B556), 16 - 32V (Ubat),
Pressure switch 1, central compressor
hydraulic system (B555), requested
Switch, auxiliary compressor
(S465)
92144/
Line number 31348
92145
Compressor valve, relay, X4/11 X1/3 0V, auxiliary ..................
auxiliary compressor (K939), compressor not ..................
Solenoid valve, compressor running
relief (Y268), 16 - 32V (Ubat),
Solenoid valve 1, auxiliary auxiliary compressor
compressor (Y390), running
Solenoid valve 2, auxiliary
compressor (Y391)
Line number 92140 31348

Auxiliary fan

Measuring instrument
FFR pin designation Desired value [V] Measured value [V]
Pin+ Pin-
Auxiliary fan valve X4/2 X1/3 0V, solenoid valve ..................
Solenoid valve, fan deactivation not activated ..................
(Y418) 16 - 32 V (Ubat),
solenoid valve
activated
Line number 92545 31348
Voltage between T-CAN Low X4/16 X1/3 0 - 32V (UBat) PWM ..................
and ground signal; control valve ..................
activated
Line number 92367 31348

CAN databus

Measuring instrument Measured value

FFR pin designation Desired value [V]
Pin+ Pin- [V]
Voltage between T-CAN High X1/14 X1/3 ~= 18 - 3.2V ..................
and ground Rectangular signal*
Line number / colour Blue/red 31348
Voltage between T-CAN Low X1/15 X1/3 ~= 18 - 3.2V ..................
and ground Rectangular signal*
Line number / colour Blue/white 31348

* check with an oscilloscope or multimeter (Scopemeter) 123 (FLUKE)

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013
 Page 26 of 26

The diagram shows signal characteristics for the CAN data bus High signal (channel A) and the CAN data
bus Low signal (channel B).

Diagnosis K-line

Measuring instrument Desired value [V] Measured value [V]

FFR pin Jumper
designation Pin+ Pin- Open Open
Closed Closed
FFR Vehicle FFR Vehicle
Voltage supply,
K-line, diagnosis
Diagnosis socket
(X200) ~= ~=
~= 22.4V .......... .......... ..........
X1/18 X1/3 14.7V 22.4V
Saturation
voltage of K-line
driver: <=20%
UBat
Input voltage Low: < 30%
UBat
..........
Input voltage High: > 70%
..........
Line number 60206 31348 UBat
..........
ZFR diagnosis, K-line
connected: 0V

Delete 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. Then delete the fault 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.

file://C:\MANWIS\XSLT\body.html?id=d0e25075 3/14/2013