Electrical System
Electronic Gearbox Control
AS-Tronic

2002 | 1 | 2 3 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12

Publication no.: System Description

81.99598-5382 2nd edition T 74

MAN Nutzfahrzeuge Aktiengesellschaft Elektrische Anlage

Dachauer Str. 667 oder Postfach 50 06 20 Systembeschreibung T 74 (2. Ausgabe)
80995 MÜNCHEN 80976 MÜNCHEN – englisch –
Printed in Germany
Electrical System

Electronic Gearbox Control

AS-Tronic
System Description T 74 (2nd edition)

81.99598-5382
ELECTRICAL SYSTEM

We reserve the right to make modifications in the course of further development.

 2002 MAN Nutzfahrzeuge Aktiengesellschaft

Reprinting, copying or translation is not allowed without written permission from MAN.
All rights under the copyright law are strictly reserved by MAN.

VSWY / HA/WT 03.2002 Übersetzung + Satz: emes GmbH

Friedrichshafen

0.01 - 2 T 74
 ELECTRICAL SYSTEM

Table of contents

Electrical system........................................................................................................................... 0
Table of contents.......................................................................................................................... 0.11 - 1
Abbreviations................................................................................................................................ 0.13 - 1

General information...................................................................................................................... 1
Notes on safety ............................................................................................................................ 1.20 - 1

System description....................................................................................................................... 2
AS-Tronic design.......................................................................................................................... 2.01 - 1
AS-Tronic advantages .................................................................................................................. 2.01 - 1
Design (electrical)......................................................................................................................... 2.01 - 2
Functions...................................................................................................................................... 2.01 - 4
AS-Tronic gearbox ....................................................................................................................... 2.01 - 5
Electronic control unit ................................................................................................................... 2.01 - 5
Speed sensor ............................................................................................................................... 2.01 - 5
Clutch actuator ............................................................................................................................. 2.01 - 6
Steering column stalk ................................................................................................................... 2.01 - 6
Mode switch ................................................................................................................................. 2.01 - 7
Display.......................................................................................................................................... 2.01 - 8
Interfaces to other systems .......................................................................................................... 2.01 - 9

Functional description ................................................................................................................. 3

Electronic control unit ................................................................................................................... 3.01 - 1
Clutch actuator ............................................................................................................................. 3.01 - 3
Speed sensor ............................................................................................................................... 3.01 - 4
Cable harness .............................................................................................................................. 3.01 - 5
Steering column stalk ................................................................................................................... 3.01 - 6
Mode switch ................................................................................................................................. 3.01 - 7
Reversing light relay ..................................................................................................................... 3.01 - 9

Component description................................................................................................................ 4
Shift module ................................................................................................................................. 4.01 - 1
Electronic control unit ................................................................................................................... 4.02 - 1
Clutch actuator ............................................................................................................................. 4.03 - 1
Speed sensor ............................................................................................................................... 4.04 - 1
Steering column stalk ................................................................................................................... 4.05 - 1
Mode switch ................................................................................................................................. 4.06 - 1

Wiring diagrams............................................................................................................................ 6
Table of contents.......................................................................................................................... 6.00 - 1
Guide to using the wiring diagrams .............................................................................................. 6.01 - 1
Overview, AS-Tronic (TG-A)......................................................................................................... 6.05 - 2
Overview, AS-Tronic (R02/R03) ................................................................................................... 6.06 - 2
Wiring diagram, AS-Tronic (12-speed) (TG-A)............................................................................. 6.20 - 2
Wiring diagram, AS-Tronic (16-speed) (TG-A)............................................................................. 6.21 - 2
Wiring diagram, drive module, AS-Tronic (R02/R03) ................................................................... 6.22 - 2
Wiring diagram, AS-Tronic (R02/R03).......................................................................................... 6.23 - 2

Diagnosis....................................................................................................................................... 8
Diagnosis socket .......................................................................................................................... 8.03 - 1
Fault code..................................................................................................................................... 8.10 - 1
Diagnosis functions ...................................................................................................................... 8.10 - 1
Malfunction indicators................................................................................................................... 8.10 - 1
Emergency functions.................................................................................................................... 8.10 - 3
On-board diagnosis ...................................................................................................................... 8.10 - 5
SPN – fault code list ..................................................................................................................... 8.10 - 7
SPN – fault code description ........................................................................................................ 8.11 - 1
System structure, K-lines ............................................................................................................. 8.15 - 1

T 74 0.11 - 1
 ELECTRICAL SYSTEM

Abbreviations As of: 04.02

a Acceleration
ABE General operating permit
ABS Anti-lock brake system
ABV Anti-skid system
AC Air conditioning
ACC Adaptive cruise control
ACK Autocheck
ADC Analog-digital converter
ADR International agreement for the transport of dangerous goods
AGB Automatic road speed limiter
AGND Analog ground
AGR Exhaust gas recirculation (EGR)
AHK Trailer coupling
AHV Trailer brake valve
ALB Automatic load-dependent brake
AMA Antenna mast system
ANH Trailer/semitrailer
AS Automated gearbox
ASD Trailer socket
ASM Trailer control module
ASR Anti-spin regulator
ASV Trailer control valve
ATC Automatic temperature control
ATF Automatic transmission fluid
AU Emission test
AV Exhaust valve
AVS Automatic gear preselection

BA Operator’s manual
BBA Service brake system
BBV Service brake valve
BKR Brake power regulator
BUGH Front heater
BV Back-up valve
BVA Brake wear indicator
BVS Brake wear sensor
BVV Brake wear sensor supply
BW German Army
BWG Brake value sensor
BZ Brake cylinder

CAN Controller area network

CAN-H CAN-high data line
CAN-L CAN-low data line
CATS Computer-assisted testing and diagnostic system
CCVS Cruise control vehicle speed
CKD Completely knocked down
CNG Compressed natural gas
CPU Central processing unit
CRT Continuously regenerating trap
CS Comfort shift

DAHL Roof ventilator

DBR Auxiliary brake relay
DECKE Cover (for doors)
DF Speed sensor
DFÜ Data transmission
DIA Diagnosis and information display

T 74 0.13 - 1
ELECTRICAL SYSTEM

Abbreviations

DIAK Diagnosis, K-line (data line)

DIAL Diagnosis, L-line (interrogation line)
DIAR Diagnosis, further interrogation
DIN German industrial standard
DKE Throttle valve increase (ASR control)
DKH Roof duct heating
DKL Roof flaps
DKR Throttle valve reduction (reduction request from ASR to EDC/EMS)
DKV Throttle valve specification (load sensor signal from EDC/EMS pedal value sensor)
DLB Compressed air brake system
DM Diagnostic message
DNR Drive - Neutral - Reverse (selector switch for automatic gearbox)
DPF Diesel particulate filter
DRM Pressure control module
DS Pressure sensor
DSV Pressure control valve
DV Throttle valve
DWA Anti-theft protection system
DZG Rpm sensor
DZM Rev counter

EBS Electronic brake system

ECAM Electronically controlled air management
ECAS Electronically controlled air suspension
ECE Emergency shut-off to ECE 36
ECU Electronic control unit
EDC Electronic diesel control
EDM Electronic diesel consumption meter
EDR Maximum speed governor
EEC Electronic engine controller
EEPROM Electrically erasable and programmable read-only memory
EFR Electronic shock absorber control (ESAC)
EFS Electrical driver’s seat
EHAB Electro-hydraulic shut-off device
ELAB Electrical shut-off device
ELF Electronic air suspension
EMS Electronic throttle control (ETC)
EMV Electromagnetic compatibility (EMC)
EOL End-of-line (programming)
EP Injection pump
ER Engine retarder (engine brake)
ESAC Electronic shock absorber control
ESP Electronic stability program
ESR Electric sun-blind
EST Electronic control unit
EV Intake valve
EVB Exhaust valve brake

FAP Driver’s area

FAQ Frequently asked questions
FBA Parking brake system
FDR Dynamic handling control
FFR Vehicle management computer (VMC)
FGB Road speed limiter (RSL)
FGR Road speed governor (RSG)
FHS Cab
FIN Vehicle identification number (VIN)
FM Vehicle management
FMI Failure mode identification

0.13 - 2 T 74
 ELECTRICAL SYSTEM

Abbreviations

FMR Vehicle/engine management

FOC Front omnibus chassis (bus/coach chassis with front-mounted engine)
FSCH Windscreen heater
FSG Ground reinforcement system
FSH Window/mirror heating
FTW Driver’s partition
FUNK Radio communication unit
FZA Destination system

GDK Controlled diesel catalytic converter

GEN Alternator
GET Gearbox
GGVS Regulations for the transport of hazardous goods
GND Ground
GP Gearbox planetary gear group (range-change box)
GS Gearbox control
GV Gearbox splitter gear group (splitter box)

HA Rear axle
HBA Auxiliary brake system
HGB Maximum road speed limiter
HGS Hydraulic gearshift
HLUE Hydrostatic fan
HOC Rear omnibus chassis (bus/coach chassis with rear-mounted engine)
HSS Highside switch
HST Main control panel
HU Main inspection
Hz Hertz (number of cycles per second)
HZA Bus stop indicator system
HZG Auxiliary rpm sensor

IBEL Interior lighting

IBIS Integrated on-board information system
IC Integrated circuit
ID Identification
IMR Integrated mechanical relay (starter control)
INA Information indicator (e.g. check lamp)
IR Individual control (ABS)
IRM Modified individual control (ABS)
ISO International Standards Organisation
IWZ Incremental angle/time measuring system

KBZ Combination brake cylinder

KFH Fuel filter heater
KITAS Kienzle intelligent tachograph sensor
KLI Air-conditioning system
KNEEL Kneeling
KSM Customer-specified control module
KSW Customer’s special request
KWP Key word protocol (protocol for MAN-cats diagnosis)

LBH Air reservoir

LCD Liquid crystal display
LDA Manifold-pressure compensator (boost control)
LDF Boost pressure sensor
LDS Air spring/damper system
LED Light emitting diode
LF Air suspension
LGS Lane guard system

T 74 0.13 - 3
ELECTRICAL SYSTEM

Abbreviations

LL Idling speed
LLA Idling speed increase
LLR Idling speed control
LNA Steering trailing axle
LNG Liquified natural gas
LOE Steering oil monitor
LPG Liquified petroleum gas
LWR Headlight beam regulator

M-TCO Modular EU tachograph

MAB Solenoid valve shut-off (engine shut-off by means of high-pressure solenoid valve in injection
pump)
MAN-cats MAN computer assisted testing and diagnostic system
MAR Solenoid valve shut-off relay (redundant engine shut-off relay)
MDB Engine speed range
MES Fuel metering control
ML Midline
MMI Man-machine interface
MOTB Engine brake
MP Engine power box (cable duct on engine block)
MR Engine governor - ASR
MSG Engine control unit (EDC)
MV Solenoid valve
MZ Diaphragm cylinder

n rpm
NA Power take-off (PTO)
NBF Needle movement sensor
NES New electronic structure
NFZ Commercial vehicle
NLA Trailing axle
NSL Rear fog lamp
NSW Front fog lamp

OBDU On-board diagnostic unit

OC Occurrence count (errors/faults)
OEAB Oil separator
OENF Oil top-up

p Pressure
PBM Pulse breadth modulation (à also see PWM)
PLM Programmable logic module
PSG Pump control unit (EDC)
PTO Power take-off
PWM Pulse width modulation (à also see PBM)

RA Repair manual
RAH Interior heating
RAM Random access memory
RAS Rear axle steering
RAS-EC Rear axle steering with electronic control
RDRA Tyre pressure control system
RDS Radio data system
RET Retarder
RKL Priority vehicle light
RLV Relay valve
RME Rape seed oil methyl ester (biodiesel)
ROM Read only memory

0.13 - 4 T 74
 ELECTRICAL SYSTEM

Abbreviations

SA Special equipment
SAE Society of Automotive Engineers
SAMT Semi-automatic mechanical transmission
SB Service outlet
sec Second
SER Series (production)
SG Control unit
SH Select-high control (ABS)
SKD Semi-knocked down
SL Select-low control (ABS)
SML Side marker light
SPN Suspect parameter number
STA Engine start/stop
SWR Headlight cleaning system

t Time
TC Traction control
TCM Trailer control module
TCO Tachograph
TKU Technical customer document
TMC Traffic message channel
TRS Technical road transport directives
TSC Torque speed control (braking torque)
TUER Door control

UBat Battery voltage

UDS Crash recorder

v Velocity/vehicle speed
VA Front axle
VG Transfer case
VLA Leading axle

WA Maintenance manual
WAB Water separator
WaPu Water pump - Intarder
WLE Swap-body unit
WR Warning relay
WS Position sensor
WSK Torque converter and clutch unit

z Braking rate/deceleration
ZBR Central on-board computer
ZBRO Central on-board bus computer
ZDR Intermediate speed governor (ISG)
ZE Central electrical system (CES)
ZR Central computer
ZS Central lubrication
ZUSH Auxiliary heater
ZWS Time-based maintenance system

λ Slip
µ Coefficient of friction
µC Microcontroller (microprocessor)

T 74 0.13 - 5
 GENERAL INFORMATION

Notes on safety

The following sections include summaries of important regulations listed according to major topics. The
intention is to provide the knowledge needed to avoid accidents which could lead to injury, damage and
environmental pollution.
Additional instructions are included in the Operator’s Manual that is provided with the vehicle.

Important:
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.

Regulations for preventing accidents leading to injury to personnel.

Only authorised technical personnel are allowed to perform inspection, adjustment and repair work.

• Secure the vehicle to prevent it from rolling away.

• Support the frame when working on the pneumatic or spring suspension
system.
• Secure units during their removal.

• Only authorised personnel are allowed to start and operate the engine.
Do not approach moving parts of a running engine too closely. Do not wear
baggy clothing.

• Do not touch the engine with your bare hands when it is at operating
temperature: Risk of burns!

• Keep the area around the engine, ladders and steps free from oil and grease.
Accidents caused by slipping can have serious consequences.
• Only use tools that are in perfect condition. Damaged or widened spanners can
slip: Risk of injury!
• No-one is allowed to stand under an engine suspended from a crane hook.
- Keep all lifting tackle in good condition -.

• Collect any brake fluid that emerges. Treat brake fluid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.
• Brake fluid is toxic! Do not allow it to come into contact with food or open
wounds.

• Do not open the coolant circuit until the engine has cooled down. If it does need
to be opened whilst the engine is at operating temperature, follow the
instructions in the "Maintenance and care" section in the Operator’s Manual.
• Do not attempt to retighten or open pipe lines and hoses (lubricating oil circuit,
coolant circuit and possible subsequent hydraulic oil circuit) whilst they are
pressurised: Fluid spraying out represents an injury hazard!
• Do not hold your hands under the jet of fuel when checking the injector nozzles.
Do not inhale fuel vapours.

T 74 1.20 - 1
GENERAL INFORMATION

• Always disconnect the batteries before working on the vehicle electrical system.
Important! Oxyhydrogen gas may form in enclosed battery boxes. When the
batteries are disconnected, this gas may be ignited by sparks produced by other
continuously operating consumers, the tachograph etc. that cannot be shut down.
Blow compressed air through the battery box before disconnecting the batteries!
• Only tow-start the vehicle if the batteries are connected (minimum charge 40%)!
Do not use a boost-charger to jump-start the vehicle! Always disconnect the
positive and negative leads before boost-charging batteries!
• Disconnect the batteries and recharge them every 4 weeks if the vehicle is not in
use.
Caution! Battery acid is poisonous and corrosive. Battery gases are explosive.
• Follow the manufacturer’s instructions for handling batteries.
• Measure voltage only using suitable measuring devices!
The input resistance of a measuring device should be at least 10 MΩ.
• The ignition must be switched off before the wiring harness plugs of electronic
control units are disconnected or connected up!
When performing electrical welding work, connect up the "ANTIZAP SERVICE
MONITOR" (MAN item number 80.78010.0001) or the improved SES-1 version
(MAN item number 80.78010.0002) in accordance with the instructions supplied with
the device.
If this device is not available, disconnect the batteries and join 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.
For further accident prevention measures, please refer to the "Leaflets for welders".
The frame is not intended for use as an earth return!
• If attachments are to be retrofitted to the vehicle – e.g. a taillift – additional earth
lines with adequate cross-section must be fitted as well. Otherwise the earth
connection may be created along wire cables, wiring harnesses, gearbox shafts,
gears etc. Severe damage could result.

• If painting work 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
around 2 hours is permissible at a maximum of 85 °C. Disconnect the batteries.

Plastic tubes (polyamide)

Important! – Risk of damage and fire!
• The warning sign opposite can be found on the co-driver’s door below the door
lock. It warns you against welding or drilling near to plastic tubes.

1.20 - 2 T 74
 GENERAL INFORMATION

Limited liability for accessories and parts

In your own interests, you are recommended to use only accessories expressly approved by MAN and
genuine MAN parts for your MAN vehicle. The reliability, safety and suitability of these parts and
accessories have been determined specifically for MAN vehicles. Despite constant market observation, we
cannot judge the aspects of other products, nor can we accept responsibility for them – even if they have
been officially approved by the German TÜV technical inspection authorities or some other official body.

Bodies and special attachments

Comply with the safety instructions and regulations issued by the bodymaker in question if bodies or
special attachments are fitted.

Taking out of operation or putting into storage

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.

T 74 1.20 - 3
 SYSTEM DESCRIPTION

AS-Tronic design

AS-Tronic is a transmission system for commercial vehicles and buses/coaches with electronic diesel
control (EDC).

Manufacturers today are constantly striving to make modern commercial vehicles easier to drive by
developing various forms of shifting aids.
Basic mechanical gearboxes are equipped with attachments such as shift cylinders, valves and sensors
(add-on solutions).
The next step is to connect these systems to control units that can control the shifts fully automatically or
semi-automatically.
The driver selects a gear using a steering column stalk/mode switch. This command is then sent to the
control unit which compares the gear selected by the driver with other input variables and then tells the
servo cylinder valves which gear to engage by sending electrical signals.
The valves control the shift cylinders pneumatically.
Sensors communicate the positions of the gearbox shift rods or shifter shafts to the control unit.

The AS-Tronic transmission system is a combination of a gearbox with electro-pneumatic shift system and
an automated clutch.
All of the gearbox functions and components are integrated inside a single unit, which means that many of
the usual electrical and pneumatic connections and lines are not needed.
The electronic control unit also controls the clutch actuator during gear selection.
EDC makes gear changes easier ("modulated revving up").

In manual mode, the driver selects the gear using a steering column stalk and mode switch.
In automatic mode, the driver only has to operate the accelerator or brake pedal. The system shifts the
gears fully automatically.

The driver no longer needs to operate the clutch as the clutch is automated. Shifting is also made easier
thanks to an electronic steering column stalk.
This steering column stalk can be operated with a minimum of effort, i.e. in semi-automatic mode, all the
driver has to do is select the gear.
The actual shift sequence is performed by the gearbox control unit. The system prevents shifting errors that
could cause damage.
The driver has the option of driving the vehicle in semi-automatic mode or fully-automatic mode. The gears
are selected automatically in fully-automatic mode, although the driver may intervene if required. The
display on the instrument panel indicates all the necessary system information for the driver, e.g. engaged
gear, gear change, clutch overload and diagnostic information.

One of the main features of the AS-Tronic transmission system is its high level of component integration.
Integrated components include the gearbox ECU, clutch actuator, Intarder, solenoid valves, position
sensors and speed sensors.

AS-Tronic advantages

− Improved reliability thanks to integrated components − No shift linkage

− Reduced logistics and service expenditure − Improved economy
− Optimum vehicle management through CAN databus − Increased driving safety
− Continual electronic system test and status − Fuel-saving driving
information for the driver on display − Low-noise gearbox
− High braking power when combined with ZF-Intarder − Optimum efficiency
− Effortless gear shifting by means of steering column stalk − Reduced clutch wear
− Easy starting off and manoeuvring – even on steep inclines − Long oil change intervals
− Fast, smooth shifts, whatever the situation on the road − Low gearbox weight
− Incorrect operation – e.g. shifting errors and, therefore, − Simple troubleshooting thanks to
impermissible engine speeds – not possible integrated fault memory and
− The driver can choose between manual and automatic diagnosis
shifts

T 74 2.01 - 1
SYSTEM DESCRIPTION

Design (electrical)

− TG-A

1 Gearbox
2 Speed sensor
3 Clutch actuator
4 Shift module with integrated electronic control unit (A330)
5 Steering column stalk, cruise control/gearbox (A429)
6 Mode switch, gearbox (A434)
7 Display (on the instrument panel A407)
8 Central on-board computer (A302)
9 Vehicle management computer (A403)

T-CAN CAN databus, drive train

I-CAN CAN databus, instrumentation

2.01 - 2 T 74
 SYSTEM DESCRIPTION

Design (electrical)

− R02/R03

1 Gearbox
2 Speed sensor
3 Clutch actuator
4 Shift module with integrated electronic control unit (A330)
5 Steering column stalk, cruise control/gearbox (A429)
6 Mode switch, gearbox (A434)
7 Display (on the instrument panel A407)
8 Multiplex node, control units 1.3 (A413)
9 Central on-board computer (A302)
10 Vehicle management computer (A403)

T-CAN CAN databus, drive train

I-CAN CAN databus, instrumentation

T 74 2.01 - 3
SYSTEM DESCRIPTION

Functions

Shifting
The clutch is disengaged and engaged automatically during shifts.
The clutch is also operated during downshifts in order to achieve synchronous speeds in the basic
gearbox by adapting the engine speed.
The engine injection quantity is influenced by means of a system interface for the electronic diesel
control (EDC) during shifts.

Shift system
The driver uses the steering column stalk (A429)/mode switch (A434) to determine the timing of the
gear change and the required gear step.
If larger gear steps are required, the driver can use a search function to engage a gear that suits the
current road speed. This means that the driver has the option of selecting an engine speed range for
optimum fuel consumption or optimum performance.

Diagnosis
If the system detects any faults during operation, even if these are only sporadic, the faults and the
environmental conditions (severity of the fault) are stored in the fault memory of the electronic control
unit (A330).
The driver is informed of any faults detected by means of the display on the instrument panel (A407).

Starter interlock
The engine can only be started when the gearbox is in "N" (neutral).
The starter circuit is connected to the gearbox neutral switch, which means that the engine cannot be
started whilst a gear is engaged.
The gearbox is shifted to "N" automatically when the engine is stopped. It is not possible to stop the
engine with a gear engaged.

Engine overspeed protection

The automated shift functions prevent engine overspeed (over-revving).
The system does not perform downshifts that could cause over-revving of the engine.

Protective functions
If the driver requests a shift that could endanger driving safety or damage the engine or gearbox, the
system will either suppress the request or select a more appropriate gear.

Limp-home (emergency control)

The limp-home device provides back-up in the event of steering column stalk or mode switch faults.
Since it is not activated automatically, it has to be activated by the driver. The separate limp-home
mode switch enables the driver to engage "2nd", "5th", "N" (neutral) and low "R" gear.
The system can still perform shifts if the compressed air supply fails, providing that there is enough
compressed air in the compressed air reservoir.
If the compressed air level falls, "AL" (AirLess) appears on the instrument panel display to warn the
driver. The compressed air system can also be re-charged from an external source, if necessary.
With respect to the transmission system, the vehicle can no longer be moved by itself under the
following conditions:
− Interruption in the vehicle voltage supply
− Insufficient compressed air
− Total failure of the electronic control module, control unit
− Failure of the driver interface and failure of the limp-home device
− Failure of the central air shut-off valve in the gearbox control unit
− Mechanical gearbox defects (no through-drive)

Important!
When the vehicle is at a standstill with the engine running and a gear engaged, pressing the
accelerator can cause the vehicle to start moving!
Always shift the gearbox to neutral and apply the parking brake before leaving the vehicle whilst
the engine is running.

2.01 - 4 T 74
 SYSTEM DESCRIPTION

Components

AS-Tronic gearbox

The gearbox is a "range-change plus splitter" transmission.

AS-Tronic gearboxes consist of a 4-gear section in the case of the 16-speed version (16 AS 2601) or a
3-gear section in the case of the 12-speed version (12 AS 2301) and 10-speed version (10 AS 2301)
as well as a splitter group or box (GV) and a range-change group or box (GP) of planetary design.

Range-change group or box

The range-change group doubles the number of forwards gear ratios from 4 to 8 (16-speed version) or
from 3 to 6 (12-speed and 10-speed version).
The range-change group has synchromesh.

Splitter group or box

The splitter group then splits these 8 or 6 gear ratios again. This gives a total of 16 or 12 forwards gear
ratios and 2 reverse gear ratios in each case. For bus and coach applications, there are 10 forwards gear
ratios and 1 reverse gear ratio. The splitter group has synchromesh.

The AS-Tronic gearbox is based on a dual-layshaft design. The main 4-gear (or 3-gear) section has a
dog-type shift mechanism.
Synchronisation is via EDC (electronic diesel control) and the transmission brake. The power arriving
from the engine is distributed evenly between the two layshafts via the input shaft. It is then returned to
the mainshaft via the currently engaged gear (dog-type shift mechanism).
In low range (e.g. gears 1-8 in the case of the 16-speed gearbox), output is via the range-change group
(GP). In high range (e.g. gears 9-16 in the case of the 16-speed gearbox), output is directly to the output
flange.
The AS-Tronic gearbox can be fitted with an Intarder/retarder.

Electronic control unit (A330)

The electronic control unit controls and monitors the AS-Tronic functions.
The control unit records various vehicle, gearbox and clutch variables and converts them into signals for
activating the gearbox, the clutch and the vehicle peripherals.
The control unit (A330) is located on the gearbox housing. Data are transferred to other systems via the
"drive train" CAN databus (T-CAN).
The control unit is EOL (end-of-line) programmed. At the end of the line, the vehicle manufacturer inputs
vehicle-specific parameters alongside the already entered system manufacturer parameters.
The entered parameters can be checked – or changed if necessary – using the MAN-cats diagnostic
system.

The shift module – which houses the integrated electronic control unit – is used to shift the gears in the
gearbox. Its task is to quickly change gear in line with the current situation on the road.
The shift module is electro-pneumatically activated by pneumatically controlled solenoid valves which, in
turn, are activated by the control unit.
Sensors record the current status of the gearbox. The gearbox input speed is measured by a speed
sensor integrated in the shift module.
As well as controlling the gearbox, the shift module also alters the clutch actuator to actuate the clutch.

Speed sensor

In manual mode, the speed sensor checks whether the selected gear can be engaged without causing
the engine to over-rev or under-rev. The gearbox output speed is taken from the TCO 1 message of the
"drive train" CAN databus (T-CAN). The speed is picked up as a signal by the speed sensor.

T 74 2.01 - 5
SYSTEM DESCRIPTION

Clutch actuator

The automatic clutch is actuated by a clutch actuator. The tasks of the clutch actuator are to disengage
and engage the clutch and, at the same time, measure the clutch setting.
This involves different speeds being set. The servo cylinder is activated pneumatically.
The cylinder is positioned by means of 4 solenoid valves. 2 valves are used for disengaging the clutch
and 2 for engaging the clutch.
The control units activates the 4 solenoid valves directly. The different speeds are assured by means of
modulated valve activation.

Steering column stalk (A429)

The AS-Tronic is operated using the steering column stalk and mode switch (A434). The driver
touches the steering column stalk to shift up or down through the gears. The steering column stalk
does not function when the mode switch is in the "N" position. The steering column stalk has an
integrated LED for the road speed governor (RSG) and the road speed limiter (RSL).
When the vehicle is at a standstill, you can:
− Select neutral (N)
− Correct the start gear max. D5 for 10 AS 2301 (10-speed)
for 12 AS 2301 (12-speed)
max. D7 for 16 AS 2601 (16-speed)
When the vehicle is in motion, you can:
− Preselect neutral (N) or
− Choose the level of automation (automatic/manual) or
− Perform manual shifts.

Before a gear change in manual mode, the speed sensor checks whether the selected gear can be
engaged without causing the engine to over-rev or under-rev.

Steering column stalk operation

Pushbutton 1 = Change between manual mode + Upshift one gear

and automatic mode ++ Upshift several gears
+ = Upshift (stalk up) - Downshift one gear
- = Downshift (stalk down) -- Downshift several gears

Note:
The steering column stalk automatically springs back to the centre position after it has been moved.

2.01 - 6 T 74
 SYSTEM DESCRIPTION

Mode switch (A434)

The AS-Tronic is operated using the mode switch and steering column stalk (A429).
In automatic mode, whilst the vehicle is in motion, none of the mode switch functions are available,
apart from the shift to "N" (neutral).
The mode switch has a built-in LED for night-lighting.

When the vehicle is at a standstill, you can select:

− Neutral (N)
− Drive direction (D = forwards; automatic/manual and R = reverse)
− Starting gear D1 - D5 for 10 AS 2301 (10-speed)
for 12 AS 2301 (12-speed)
D1 - D7 for 16 AS 2601 (16-speed)
− Manoeuvring mode (DM, RM)

The selected settings are sent to the electronic control unit (A330).

If the vehicle comes to a standstill and the mode switch is still in one of the D or R positions, the signal
for neutral position (N) is sent to the electronic control unit.

If the vehicle comes to a standstill and the vehicle management computer (A403) receives a gear
signal from the control unit, this gear is compared with the selected start gear.
The vehicle management computer selects the lower of the two gears and sends the signal back to the
electronic control unit.

In manual mode, the vehicle management computer (A403) must always record the previous drive
direction when a shift to neutral or a change from D to R (or vice versa) takes place. If the driver then
turns the mode switch back to the previous position, the system will engage a suitable gear again.

Mode switch: 10 AS 2301 (10-speed)

12 AS 2301 (12-speed)

N = Neutral
DM = Forwards manoeuvring
D1 = Forwards drive with starting gear 1
D3 = Forwards drive with starting gear 3
D5 = Forwards drive with starting gear 5
R1 = Reverse
RM = Reverse manoeuvring

Mode switch: 16 AS 2601 (16-speed)

N = Neutral
DM = Forwards manoeuvring
D1 = Forwards drive with starting gear 1
D4 = Forwards drive with starting gear 4
D7 = Forwards drive with starting gear 7
R1 = Reverse
RM = Reverse manoeuvring

T 74 2.01 - 7
SYSTEM DESCRIPTION

Display

The display is integrated in the instrument panel (A407). All the information for the driver and workshop
is displayed.

Display segments

3 4 5

1 Diagnosis

7 6

1 TCU = Transmission Control Unit

2 03004-05 = Fault code

3 M = Manoeuvring mode

4 = A triple downshift is currently possible

5 4 = Gear indicator (P122)

6 = Gearbox status monitor check lamp (H179)

7 = Central warning light (H111)

2.01 - 8 T 74
 SYSTEM DESCRIPTION

Interfaces to other systems

Thanks to its inclusion in the CAN databus, AS-Tronic can be networked with other systems.
Data are transferred between the individual systems via the serial "drive train" CAN databus (T-CAN)

− TG-A

A143 Electronic air suspension/ A403 Vehicle management computer with

electronic shock absorber control terminators, M-CAN and T-CAN
A144 Control, retarder/Intarder A407 Instrumentation
A302 Central computer 2 with terminator, I-CAN A408 Tachograph with terminator, I-CAN
A312 Customer-specified module A409 Electronically controlled air management with
terminator, T-CAN
A330 Gearbox control, Tipmatic AS-Tronic A435 Electronic diesel control with terminator, M-CAN
A384 Rear axle steering RAS-EC A551 Drive module, oil level sensor
A402 Electronic brake system

I-CAN CAN databus, instrumentation T-CAN CAN databus, drive train

M-CAN CAN databus, engine management

T 74 2.01 - 9
SYSTEM DESCRIPTION

− Buses and coaches R02 and R03 (multiplex)

A408 Tachograph with terminator, I-CAN A144 Control, retarder/Intarder

A435 Electronic diesel control with A143 Electronic air suspension/
terminator, M-CAN electronic shock absorber control
A403 Vehicle management computer with A330 Gearbox control, Tipmatic AS-Tronic
terminators, M-CAN and T-CAN
A360 Multiplex, central computer A407 Instrumentation
A302 Central computer 2 with terminator, I-CAN A551 Drive module, oil level sensor
A402 Electronic brake system A409 Electronically controlled air management with
A312 Customer-specified module terminator, T-CAN

Basis-CAN1 CAN databus, multiplex line 1 I-CAN CAN databus, instrumentation

Basis-CAN2 CAN databus, multiplex line 2 M-CAN CAN databus, engine management
T-CAN CAN databus, drive train

A411 Multiplex node, front left 1.1 A421 Multiplex node, front right 2.1
A413 Multiplex node, control units 1.3 A422 Multiplex node 2.2
A417 Multiplex node 1.7 A423 Multiplex node, vehicle centre 2.3
A418 Multiplex node, rear right 1.8 A428 Multiplex node, rear left 2.8

R195 Terminator, front, basis CAN 1 R197 Terminator, front, basis CAN 2
R196 Terminator, rear, basis CAN 1 R198 Terminator, rear, basis CAN 2

2.01 - 10 T 74
 FUNCTIONAL DESCRIPTION

Electronic control unit (A330)

The voltage supply (voltage, terminal 30) comes from the central electrical system (A100). The control unit
integrated in the shift module processes input signals that it receives via speed sensor, position sensor and
the "drive train" databus (T-CAN): When the ignition is activated (voltage, terminal 15), the electronic
control unit checks the clutch actuator, activates the 4 solenoid valves in the clutch actuator and monitors
the clutch setting by means of a position sensor integrated in the sensor unit.
The control unit checks the specified gear. The input signals from the steering column stalk (A429) and the
mode switch (A434) are recorded by the vehicle management computer (A403) and converted into a
databus format. From here, the signals are sent to the central on-board computer (A302) via the CAN
databus (T-CAN). The central on-board computer then informs the control unit. Signal output is via the
T-CAN.
If faults occur, the fault codes stored in the fault memory of the electronic control unit can be read out via
the diagnosis K-line using MAN-cats II.

Connector pin assignment

(vehicle manufacturer scope)

The following connector pin assignment

is documented on the wiring diagram.

(20-pole screw/plug connection)

Pin Line no. Designation Signal

A1 40004 VPI Voltage supply, terminal 15 (ignition "ON")
Fuse, gearbox (terminal 15) (F154)
A2 40201 SDDK Diagnosis, K-line
Plug connection, diagnosis (MAN-cats) (X200)
A4 40008 VPE1 Voltage supply, terminal 30 (continuous positive)
Fuse, gearbox (terminal 30) (F196)
A5 40008 VPE2 Voltage supply, terminal 30 (continuous positive)
Fuse, gearbox (terminal 30) (F196)
A8 --- CANF1-H CAN databus, drive train, High to
central computer 2 (A302) – TG-A
control unit, retarder (A144) – R02/R03
A12 --- CANF1-L CAN databus, drive train, Low to
central computer 2 (A302) – TG-A
control unit, retarder (A144) – R02/R03
A13 --- CANF1-L+ CAN databus, drive train, Low to
control unit, ECAM (A409) – TG-A
central computer 2 (A302) – R02/R03
A14 --- CANF1-H+ CAN databus, drive train, High to
control unit, ECAM (A409) – TG-A
central computer 2 (A302) – R02/R03
A16 31000 VM1 Ground
Threaded pin M6 (engine power box) (X1904)
A17 31000 VM2 Ground
Threaded pin M6 (engine power box) (X1904)

T 74 3.01 - 1
FUNCTIONAL DESCRIPTION

Connector pin assignment

(Gearbox manufacturer scope)

The following connector pin assignment

is not documented on the wiring diagram.

(20-pole screw/plug connection)

Pin Designation Component Signal

B6 VMGA2 Speed sensor Ground
B7 ADS1 Clutch actuator Clutch close, slow
B8 ADS3 Clutch actuator Clutch close, fast
B9 ADS2 Clutch actuator Clutch open, slow
B10 EU1 Clutch actuator Position sensor signal
B11 EF Speed sensor Speed signal
B12 ADS4 Clutch actuator Clutch open, fast
B15 AU Clutch actuator Voltage supply, position sensor
B16 VM1 Clutch actuator Ground, solenoid valves, slow
B17 VM2 Clutch actuator Ground, solenoid valves, fast
B18 ADVP Speed sensor Voltage supply
B20 VGMA1 Clutch actuator Ground, sensor

Technical data (shift module)

Rated voltage: 24V

Operating voltage range: 18V – 32V
Closed-circuit current consumption: 5mA
Overvoltage: 36V/1 hour at 40 °C ambient temperature

3.01 - 2 T 74
 FUNCTIONAL DESCRIPTION

Clutch actuator

The tasks of the clutch actuator are to disengage and engage the clutch and, at the same time, measure
the clutch setting. This involves defined speeds being set. The servo cylinder is pneumatically actuated and
positioned by means of 4 solenoid valves, 2 of which are for disengaging the clutch and 2 of which are for
engaging the clutch.
Solenoid valve Y16 ("air in, fast" 4 ) sends unrestricted air into the servo cylinder and swiftly separates the
clutch.
Solenoid valve Y17 ("air in, slow" 5 ) sends restricted air 7 into the servo cylinder and smoothly separates
the clutch.
Solenoid valve Y14 ("air out, fast" 3 ) removes unrestricted air from the servo cylinder and swiftly engages
the clutch.
Solenoid valve Y15 ("air out, slow" 6 ) removes restricted air 7 from the servo cylinder and smoothly
engages the clutch.
The 4 solenoid valves in the clutch actuator are activated by the electronic control unit (A330). The internal
resistance of the solenoids is 14 – 20Ω.
The position sensor 2 records the clutch positions and detects the degree of clutch engagement. The
clutch wear path is verified and adapted.

Wiring diagram

1 Clutch actuator 6 Solenoid valve Y15 (air out, slow)

2 Position sensor 7 Restrictor (slow)
3 Solenoid valve Y14 (air out, fast)
4 Solenoid valve Y16 (air in, fast)
5 Solenoid valve Y17 (air in, slow)

I Air out II Compressed air

Pin assignment

A Positive signal, solenoid valve Y15 G Voltage supply, position sensor

B Positive signal, solenoid valve Y14 H Ground, position sensor
C Ground, Y14 and Y16 I Signal, position sensor
D Positive signal, solenoid valve Y16 J Ground, Y15 and Y17
E Positive signal, solenoid valve Y17

T 74 3.01 - 3
FUNCTIONAL DESCRIPTION

Connector pin assignment

(Gearbox manufacturer scope)

The following connector pin assignment

is not documented on the wiring diagram.

Pin Components Signal

A Solenoid valve, air out, slow (Y15) Positive
B Solenoid valve, air out, fast (Y14) Positive
C Solenoid valves, fast (Y14, Y16) Ground
D Solenoid valve, air in, fast (Y16) Positive
E Solenoid valve, air in, slow (Y17) Positive
F Temperature signal, sensor Signal
G Supply, position sensor Positive/5V
H Supply, position sensor Ground
I Position sensor Signal
J Solenoid valves, slow (Y15, Y17) Ground

Speed sensor

In manual mode, the task of the speed sensor is to check whether the selected gear can be engaged
without causing the engine to over-rev or under-rev. The gearbox output speed is taken from the TCO 1
message of the "drive train" CAN databus (T-CAN). The speed sensor is activated by the electronic control
unit (A330).
The gearbox output speed is picked up as a signal by the speed sensor.

Wiring diagram
Voltage supply
1 (+24V)

Speed
3 sensor
Signal

2 Ground

3.01 - 4 T 74
 FUNCTIONAL DESCRIPTION

Connector pin assignment

(Gearbox manufacturer scope)

The following connector pin assignment

is not documented on the wiring diagram.

Pin Designation
1 Voltage supply, speed sensor
2 Ground, speed sensor
3 Signal, speed sensor

Technical data

Speed sensor voltage: 6.5V

Speed sensor ground: 0V
Speed sensor signal: 8 pulses/revolution

Cable harness (gearbox manufacturer scope)

A cable harness with moulded plugs is used to connect the shift module, clutch actuator and speed sensor.
It is not possible to repair a defective cable harness.

Shift module Speed sensor Clutch actuator Signal

Pin Pin Pin
B6 2 --- Ground, speed sensor
B7 --- A Clutch close, slow
B8 --- B Clutch close, fast
B9 --- E Clutch open, slow
B10 --- I Signal, position sensor
B11 3 --- Signal, speed sensor
B12 --- D Clutch open, fast
B15 --- G Voltage supply, position sensor
B16 --- J Ground, solenoid valves, slow
B17 --- C Ground, solenoid valves, fast
B18 1 --- Voltage supply, speed sensor
B20 --- H Ground, position sensor

T 74 3.01 - 5
FUNCTIONAL DESCRIPTION

Steering column stalk (A429)

The voltage supply comes from the central electrical system (A100). The steering column stalk has a built-
in LED (H378) for the road speed governor (RSG) and the road speed limiter (RSL).
The LED is activated by the vehicle management computer (A403).
The driver uses the steering column stalk/mode switch (A434) to select a gear. The pushbutton on the
steering column stalk can be used by the driver to switch between manual mode and automatic mode and
vice versa.
The input signals from the steering column stalk and mode switch (A434) are recorded by the vehicle
management computer (A403) and converted into a databus format.
From here, the signals are sent to the central on-board computer (A302) via the "drive train" CAN databus
(T-CAN). The central on-board computer then sends the signals to the electronic control unit (A330) via the
CAN databus (T-CAN). The control unit then performs the desired gear shift and informs the vehicle
management computer (A403) of possible gears that can be engaged, i.e. the lowest and highest possible
gears.
Press the pushbutton to change from automatic mode to manual mode. The vehicle management computer
(A403) then sends the signal for the gear that is currently engaged to the electronic control unit (A330).
Manual mode is now activated, and the current gear is retained. The driver can engage a suitable gear by
moving the steering column stalk upwards or downwards. The signal for the desired gear is sent to the
electronic control unit (A330) via the CAN databus (T-CAN).
Simply press the pushbutton to change from manual mode to automatic mode.
The steering column stalk does not function when the mode switch (A434) is in the "N" position.

Wiring diagram

Voltage supply
(+24V)

Control circuit Clock signal

LED anode

Data signal

Ground

Connector pin assignment

3.01 - 6 T 74
 FUNCTIONAL DESCRIPTION

Pin Line no. Line colour Designation

1 31000 Brown Ground, steering column stalk
2 60608 White Clock line
Vehicle management computer (A403 pin X1/7)
3 60609 Green/yellow Control circuit, LED, anode
Vehicle management computer (A403 pin X2/17)
4 60607 Blue Data line
Vehicle management computer (A403 pin X2/8)
5 --- --- Not used
6 60028 Black Voltage supply, steering column stalk (+24V)

Technical data:

Operating voltage: 16 – 32V

Overvoltage: 36V / 1 hour at 40 °C ambient temperature
Test voltage: 27.6V
Rated voltage: 24V
Minimum current at 16V: approx. 21mA (combined with veh. management comp. A403)
Maximum current at 32V: approx. 24mA (combined with veh. management comp. A403)
LED colour in handle: Yellow
Preresistance, LED: 1kΩ
Operating temperature: -40 ....+80 °C

Input: Input resistance: 5kΩ to 24V

125kΩ to ground
Switching points: low < 4V
high > 10V
Input capacitance: 1nF

Output: Maximum input current: 100mA

Output impedance: 5kΩ
Output level: low < 0.5V (100mA)
high > 5kΩ at 24V
Output capacitance: 1nF

Mode switch (A434)

The voltage supply comes from the central electrical system (A100). This voltage is also supplied to the
steering column stalk (A429).
The mode switch has an integrated LED for night-lighting. The LED is supplied with voltage from the central
electrical system (A100).
The driver uses the mode switch/steering column stalk (A429) to select a gear. The input signals from the
mode switch and steering column stalk (A429) are recorded by the vehicle management computer (A403)
and converted into a databus format.
From here, the signals are sent to the central on-board computer (A302) via the "drive train" CAN databus
(T-CAN). The central on-board computer then sends the signals to the electronic control unit (A330) via the
CAN databus (T-CAN). The control unit then performs the desired gear shift and informs the vehicle
management computer (A403) of possible gears that can be engaged, i.e. the lowest and highest possible
gears.
Note that, in automatic mode (whilst the vehicle is in motion), the mode switch does not have any functions
apart from shift to neutral "N".
If, in manual mode, the mode switch is turned to the neutral position or the drive direction is changed
(D to R or R to D), the vehicle management computer (A403) will store the previous drive direction.
If the mode switch is then turned back to the position (drive direction) stored in the vehicle management
computer (A403), the system will engage a suitable gear again.

T 74 3.01 - 7
FUNCTIONAL DESCRIPTION

Wiring diagram

Voltage
supply (24V)

Ctrl. circuit
LED anode

Clock signal

Control circuit Data signal

LED cathode

Ground

Connector pin assignment

The 10 AS 2301 (10-speed), 12 AS 2301 (12-speed) and 16 AS 2601 (16-speed) gearboxes have an
identical connector pin assignment.

Pin Line no. Designation

1 --- Not used
2 60615 Clock line
Vehicle management computer (A403 pin X1/8)
3 58000 Control circuit, LED, anode
4 60616 Data line
Vehicle management computer (A403 pin X2/7)
5 31000 Control circuit, LED, cathode
6 60028 Voltage supply, mode switch (+24V)
7 --- Not used
8 31000 Ground, mode switch

3.01 - 8 T 74
 FUNCTIONAL DESCRIPTION

Technical data:

Operating voltage: 16 – 32V

Overvoltage: 36V / 1 hour at 40 °C ambient temperature
Test voltage: 27.6V
Rated voltage: 24V
Function: Minimum current at 16V: 5.9mA
Maximum current at 32V: 8.5mA
Lighting: Minimum current at 16V: 4.7mA
Maximum current at 32V: 11.3mA
Operating temperature: -40 ....+80 °C
Night-lighting: LED super-red
Input: Input resistance: 5kΩ to 24V
125kΩ to ground
Switching points: low < 4V
high > 10V
Input capacitance: 1nF
Output: Maximum input current: 100mA
Output impedance: 5kΩ
Output level: low < 0.5V (100mA)
high > 5kΩ at 24V
Output capacitance: 1nF

Reversing light relay (K250)

The reversing light comes on as soon as reverse gear is activated. The signal from the mode switch (A434)
is recorded in the vehicle management computer (A403) and converted into a databus format.
From here, the signal is then sent to the central on-board computer (A302) in T-CAN format. The reversing
light relay is activated from the central on-board computer.
The voltage supply for the relay comes from the central electrical system (A100).

T 74 3.01 - 9
 COMPONENT DESCRIPTION

Shift module
1 2 3
Design

The following components are integrated in the shift

module:

− The electronic control unit - controls and monitors the AS-Tronic functions
4 shift cylinders One each for shifting the splitter group 1 , the gearbox main section 2 ,
and the range-change group 3 as well as one for the selector device
in the gearbox main section 4
− Solenoid valves For electropneumatic activation of the shift module
Position sensors For recording the shift travel and shift positions in the gearbox
− Speed sensor For measuring the gearbox input speed
Pressure sensor For recording the operating pressure, sent to the electronic control unit in
the form of a sensor signal; the signal is used for monitoring and
diagnosis functions
− Pressure limiting valve For reducing the vehicle operating pressure to the required level;
performs the function of a compressed air port at the same time
− 2x 20-pole plug connections

Installation position

TG-A:
1
The shift module 1 is mounted on top of the gear-
box.

R02/R03:

The shift module 1 is mounted on top of the gearbox

1
(rear seat row – open front hatch).

T 74 4.01 - 1
 COMPONENT DESCRIPTION

Electronic control unit (A330)

Design

The automated manual gearbox has an electronic

control unit which is integrated in the shift module.
The control unit contains the components for shifting
the gears, selecting the gears, controlling the clutch
and communicating with other control units via the
CAN databus.
The electronic gearbox control unit is based on a
16-bit microcomputer.
The control unit electronic system has integrated A330
circuits, microcontrollers and other electronic
components.
The control systems for the necessary auxiliary units
(retarder/Intarder, power take-offs) are also included.
The control unit is protected against wrong pole
connection, overvoltage and short-circuits.

Installation position

TG-A: 2 A330 1

The control unit is mounted on top of the gearbox.

It is connected to the vehicle electrical system/

central electrical system (voltage supply and CAN
data line) by means of the screw/plug connection 1 .
It is connected to the gearbox (clutch actuator and
speed sensor) by means of the screw/plug
connection 2 .

R02/R03:

The control unit is mounted on top of the gearbox

(rear seat row – open front hatch). A330
It is connected to the vehicle electrical system/ 2 1
central electrical system (voltage supply and CAN
data line) by means of the screw/plug connection 1 .
It is connected to the gearbox (clutch actuator and
speed sensor) by means of the screw/plug
connection 2 .

T 74 4.02 - 1
 COMPONENT DESCRIPTION

Clutch actuator

Design

The tasks of the clutch actuator are to disengage

and engage the clutch and, at the same time,
measure the clutch setting. The servo cylinder has a
total stroke of 70 mm.
Solenoid valves Y14 – Y17 (for "air in" and "air out")
and a position sensor (for recording the clutch
positions and the degree of clutch engagement) are
integrated in the clutch actuator.

Installation position

The clutch actuator 1 is mounted on the bottom of

the gearbox.

T 74 4.03 - 1
 COMPONENT DESCRIPTION

Speed sensor

Design

In manual mode, the speed sensor checks whether

the selected gear can be engaged without causing
the engine to over-rev or under-rev.

Installation position

The speed sensor (see arrow) is installed on the left

of the gearbox (looking towards the front of the
vehicle).

T 74 4.04 - 1
 COMPONENT DESCRIPTION

Steering column stalk (A429)

Design A429
1
The driver uses the steering column stalk to select
the gears. The steering column stalk has a total of
7 shift functions and contains an LED for the road
speed governor and road speed limiter.
In manual mode (semi-automatic mode), the driver
selects the gears. Lightly tap the steering column
stalk upwards or downwards once to perform an
upshift or downshift respectively.
To change from manual mode to automatic mode,
press the pushbutton 1 on the end. The driver only
has to press the accelerator or brake pedal, i.e. the
AS-Tronic performs the actual gear shifts. Press the
pushbutton 1 again to change back to manual mode.

Installation position

TG-A:

The steering column stalk is located on the right-

hand side of the steering column.

A429

R02/R03:

The steering column stalk is located on the right-

hand side of the steering column.

A429

T 74 4.05 - 1
 COMPONENT DESCRIPTION

Mode switch (A434)

Design A434

The driver uses the mode switch to select the gears.

The mode switch has a total of 7 shift positions and
contains an LED for night-lighting.
It has an 8-pole connection and is electrically
connected to the vehicle management computer
which then registers the input signals.
In automatic mode, whilst the vehicle is in motion,
none of the mode switch functions are available,
apart from the shift to "N" (neutral).

Installation position

TG-A:

The mode switch is installed in the centre console.

A434

R02/R03:

The mode switch is installed in the instrument panel

area.

A434

T 74 4.06 - 1
 WIRING DIAGRAMS

Table of contents

Diagram title Diagram no. Section/page

Guide to using the wiring diagrams 6.01 - 1

Installation positions, TG-A 6.01 - 2
Installation positions, R02 6.01 - 6
Overview, AS-Tronic (TG-A) 6.05 - 2
Overview, AS-Tronic (R02/R03) 6.06 - 2
Wiring diagram, AS-Tronic (12-speed) (TG-A) 81.99192.2993 6.20 - 2
Wiring diagram, AS-Tronic (16-speed) (TG-A) 81.99192.2992 6.21 - 2
Wiring diagram, drive module, AS-Tronic (R02/R03) 81.99289.5769 6.22 - 2
Wiring diagram, AS-Tronic (R02/R03) 81.99289.5810 6.23 - 2

T 74 6.00 - 1
 WIRING DIAGRAMS

Guide to using the wiring diagrams

1 Component designation (here: Diode V100, central electrical system, number 53)
2 Installation position at the front end of the central electrical system (here: Stamped number 53)
3 Plug connection at the rear end of the central electrical system (here: Plug 78, connection 8)
4 Line number; repeatedly printed along the length of the wire (cross-section is only printed if larger
than 12)
5 Sheet number (not page number) and current path number
Indication of sheet number and current path on which the line continues
(here: Line 31002 continues on sheet 2 and current path 4)
6 Plug connection (here: 1-pole plug connection X104 in CES area)
7 Component installation position (here: 21-pole plug connection X238 pin R
– cab to engine cable line – in mid-section)
8 Current path number (Important: Each sheet is again numbered from 1 to 55)

Important note regarding use of the diagram keys: Some of the item numbers are followed by a three-
digit number in brackets. This three-digit number is the component code number!
These code numbers appear on the list of equipment in T60.

T 74 6.01 - 1
 WIRING DIAGRAMS

Installation positions for left-hand drive vehicles (TG-A)

6.01 - 2 T 74
 WIRING DIAGRAMS

Identifier Installation position

A
.................................................................................................. Rear of vehicle
B1
.................................................................................................. Engine
B2
.................................................................................................. Gearbox
C
.................................................................................................. Front of vehicle
C1
.................................................................................................. Bumper
C2
.................................................................................................. Right-hand entry point
C3
.................................................................................................. Left-hand entry point
E6
.................................................................................................. Area of central electrical system
E7
.................................................................................................. Control unit plug-in modules
E8
.................................................................................................. Back wall of cab
F
.................................................................................................. Instrument panel
F1
.................................................................................................. Mid-section
F2
.................................................................................................. Steering column/steering wheel
F3
.................................................................................................. Pedals
F4
.................................................................................................. Front wall inside left
F5
.................................................................................................. Front wall inside right
F6
.................................................................................................. Driver’s seat
F7
.................................................................................................. Co-driver’s seat
F8
.................................................................................................. Gearshift console
G
.................................................................................................. Battery box
H1
.................................................................................................. B-pillar, driver's side
H2
.................................................................................................. A-pillar, driver's side
J1
.................................................................................................. B-pillar, co-driver's side
J2
.................................................................................................. A-pillar, co-driver's side
L
.................................................................................................. Ceiling/roof
N
.................................................................................................. Front axle
P
.................................................................................................. Rear axle
R1
.................................................................................................. Front frame sections
R2
.................................................................................................. Rear frame section
S1
.................................................................................................. Left-hand door
S2
.................................................................................................. Right-hand door

T 74 6.01 - 3
 WIRING DIAGRAMS

Installation positions for right-hand drive vehicles (TG-A)

6.01 - 4 T 74
 WIRING DIAGRAMS

Identifier Installation position

A
.................................................................................................. Rear of vehicle
B1
.................................................................................................. Engine
B2
.................................................................................................. Gearbox
C
.................................................................................................. Front of vehicle
C1
.................................................................................................. Bumper
C2
.................................................................................................. Right-hand entry point
C3
.................................................................................................. Left-hand entry point
E6
.................................................................................................. Area of central electrical system
E7
.................................................................................................. Control unit plug-in modules
E8
.................................................................................................. Back wall of cab
F
.................................................................................................. Instrument panel
F1
.................................................................................................. Mid-section
F2
.................................................................................................. Steering column/steering wheel
F3
.................................................................................................. Pedals
F4
.................................................................................................. Front wall inside left
F5
.................................................................................................. Front wall inside right
F6
.................................................................................................. Driver’s seat
F7
.................................................................................................. Co-driver’s seat
F8
.................................................................................................. Gearshift console
G
.................................................................................................. Battery box
H1
.................................................................................................. B-pillar, driver's side
H2
.................................................................................................. A-pillar, driver's side
J1
.................................................................................................. B-pillar, co-driver's side
J2
.................................................................................................. A-pillar, co-driver's side
L
.................................................................................................. Ceiling/roof
N
.................................................................................................. Front axle
P
.................................................................................................. Rear axle
R1
.................................................................................................. Front frame sections
R2
.................................................................................................. Rear frame section
S1
.................................................................................................. Left-hand door
S2
.................................................................................................. Right-hand door

T 74 6.01 - 5
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Installation positions, R02

Location identifiers Installation position

A .............................................................................................................. Rear of vehicle

B .............................................................................................................. Engine, gearbox
C .............................................................................................................. Front of vehicle
D .............................................................................................................. Main switchboard
E .............................................................................................................. Equipment compartment (battery box)
E1 .............................................................................................................. Equipment board 1 (sec. switchboard)
E6 .............................................................................................................. Area of central electrical system (CES)
E7 .............................................................................................................. Control unit plug-in modules
F .............................................................................................................. Instrument panel
G .............................................................................................................. Battery box (front)
G1 .............................................................................................................. Battery box (rear)
H .............................................................................................................. Left-hand side of vehicle
J .............................................................................................................. Right-hand side of vehicle
K .............................................................................................................. Middle of vehicle
L .............................................................................................................. Ceiling
N .............................................................................................................. Front axle
P .............................................................................................................. Rear axle

6.01 - 6 T 74
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T 74 6.05 - 1
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Overview, AS-Tronic (TG-A)

Key
Modification status: 04.01

A100 Central electrical system 1 Clutch close, fast 7 Ground, position sensor
A143 Control unit, ECAS
A144 Control unit, retarder 2 Ground, solenoid valves, fast 8 Signal, position sensor
A189 Tail light, left
A190 Tail light, right 3 Clutch open, fast 9 Voltage supply, position sensor
A302 Central computer 2
A330 Control unit, AS-TRONIC (on gearbox) 4 Clutch open, slow 10 Voltage supply Speed sensor
A312 Customer-specified control module
A384 Control unit, rear axle steering 5 Ground, solenoid valves, slow 11 Signal, speed sensor
A402 Control unit, EBS
A403 Vehicle management computer 6 Clutch close, slow 12 Ground, speed sensor
A407 Instrumentation
A409 Control unit, ECAM
A429 Steering column stalk (cruise control/gearbox) Line colours
A551 Control unit, oil level sensor
A434 Mode switch (gearbox) blrt Blue/red
E102 Reversing light, right blws Blue/white
E103 Reversing light, left blge Blue/yellow
F125 Fuse, instrument, switch and location lighting gebl Yellow/blue
F154 Fuse, gearbox (terminal 15)
F196 Fuse, gearbox (terminal 30)
F314 Fuse, reversing light, parking brake, external consumers X1642 Earthing point, cab, behind instrument panel
F583 Fuse, VMC (term. 15) switches/sensors X1644 Earthing point, cab, next to central electrical system
H179 Check lamp, gearbox, status monitor X1693 Crimped connector, line 60028
H378 Check lamp, RSG/RSL (LED) X1827 Crimped connector, line 31000
K250 Relay, reversing light X1831 Crimped connector, line 60028
P122 Gear indicator X1832 Crimped connector, line 60028
X200 Plug connection, 37-pole, diagnosis (MAN-cats) X1834 Crimped connector, line 71300
X1544 Plug connection, frame III X1904 Threaded pin M6 (engine power box)
X1553 Plug connection, engine/EDC/gearbox III X1948 Plug connection, engine/gearbox (engine power box)
X1559 Plug connection, engine/EDC/gearbox IV X2043 Plug connection, adaptation, AS-TRONIC
X2400 Crimped connector, line, blue/red
X2401 Crimped connector, line, blue/white
A Speed sensor X2542 Potential distributor, 21-pole, line 58000
X2544 Potential distributor, 21-pole, K-line
B Clutch actuator

T 74 6.05 - 2
 WIRING DIAGRAMS
Overview, AS-Tronic (TG-A)

T 74 6.05 - 3
 WIRING DIAGRAMS

T 74 6.06 - 1
 WIRING DIAGRAMS

Overview, AS-Tronic (R02/R03)

Key
Modification status: 10.00 / 09.01

A100 Central electrical system 1 Clutch close, fast 7 Ground, position sensor
A143 Control unit, ECAS
A144 Control unit, retarder 2 Ground, solenoid valves, fast 8 Signal, position sensor
A189 Tail light, left
A190 Tail light, right 3 Clutch open, fast 9 Voltage supply, position sensor
A302 Central computer 2
A330 Control unit, AS-TRONIC (on gearbox) 4 Clutch open, slow 10 Voltage supply, speed sensor
A402 Control unit, EBS
A403 Vehicle management computer 5 Ground, solenoid valves, slow 11 Signal, speed sensor
A407 Instrumentation
A409 Control unit, ECAM 6 Clutch close, slow 12 Ground, speed sensor
A413 Multiplex node, front, control units 1.3
A429 Steering column stalk (cruise control/gearbox)
A434 Mode switch (gearbox) Line colours
E102 Reversing light, right
E103 Reversing light, left blrt Blue/red
F125 Fuse, instrument, switch and location lighting blws Blue/white
F154 Fuse, gearbox (terminal 15) blge Blue/yellow
F196 Fuse, gearbox (terminal 30) gebl Yellow/blue
F314 Fuse, reversing light, parking brake, external consumers
F372 Fuse, VMC (term. 15) switches/sensors
H179 Check lamp, gearbox, status monitor X1693 Crimped connector, line 60028
H378 Check lamp, RSG/RSL (LED) X1904 Threaded pin M6 (engine power box)
K250 Relay, reversing light X1908 Crimped connector, K-KWP2
P122 Gear indicator X3013 Plug connection, instrument panel 1
X200 Plug connection, 37-pole, diagnosis (MAN-cats)
X617 Distributor, terminal board X102, line 31000
X618 Distributor, terminal board X102, line 31000
X987 Plug connection, main harness-rear
X1553 Plug connection, engine/EDC/gearbox III

A Speed sensor
B Clutch actuator

T 74 6.06 - 2
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Overview, AS-Tronic (R02/R03)

T 74 6.06 - 3
 WIRING DIAGRAMS

T 74 6.20 - 1
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Gearbox, AS-TRONIC (12-SPEED) (TG-A)

Codes for installation positions
Key
Diagram no. 81.99192.2993 Sheet 1 of 2 A Rear of vehicle F6 Driver’s seat
Modification status: 04.01 B1 Engine F7 Co-driver’s seat
B2 Gearbox F8 Gearshift console
A = Voltage supply
B = Diagnosis C Front of vehicle G Battery box
C = Gear indicator, check lamp C1 Bumper H1 B-pillar, driver's side
C2 Right-hand entry point H2 A-pillar, driver's side
A100 (255) Central electrical system
A302 (352) Central computer 2
C3 Left-hand entry point J1 B-pillar, co-driver's side
A330 (442) Control unit, AS-TRONIC (on gearbox) E6 Area of central electrical system J2 A-pillar, co-driver's side
A407 (342) Instrumentation E7 Control unit plug-in modules L Ceiling/roof
E8 Back wall of cab N Front axle
F154 (118) Fuse, gearbox (terminal 15)
F196 (118) Fuse, gearbox (terminal 30)
F Instrument panel P Rear axle
F1 Mid-section R1 Front frame section
H179 Check lamp, gearbox, status monitor F2 Steering column/steering wheel R2 Rear frame section
F3 Pedals S1 Left-hand door
P122 Gear indicator
F4 Front wall inside left S2 Right-hand door
X1553 Plug connection, engine/EDC/gearbox III F5 Front wall inside right
X1904 Threaded pin M6 (engine power box)
X1948 Plug connection, engine/gearbox (engine power box)
X2544 (246) Potential distributor, 21-pole, K-line

T 74 6.20 - 2
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Diagram no. 81.99192.2993 Sheet 1 of 2

T 74 6.20 - 3
 WIRING DIAGRAMS

Gearbox, AS-TRONIC (12-SPEED) (TG-A)

Codes for installation positions
Key
Diagram no. 81.99192.2993 Sheet 2 of 2 A Rear of vehicle F6 Driver’s seat
Modification status: 04.01 B1 Engine F7 Co-driver’s seat
B2 Gearbox F8 Gearshift console
A = Gear select, cruise control
B = Mode select C Front of vehicle G Battery box
C = Control circuit, reversing light C1 Bumper H1 B-pillar, driver's side
C2 Right-hand entry point H2 A-pillar, driver's side
A100 (255) Central electrical system
A302 (352) Central computer 2
C3 Left-hand entry point J1 B-pillar, co-driver's side
A403 (339) Vehicle management computer E6 Area of central electrical system J2 A-pillar, co-driver's side
A429 (401) Steering column stalk, cruise control/gearbox E7 Control unit plug-in modules L Ceiling/roof
A434 (402) Mode switch, gearbox E8 Back wall of cab N Front axle
F314 (101) Fuse, reversing light F Instrument panel P Rear axle
F1 Mid-section R1 Front frame section
H378 Check lamp, RSG/RSL (LED) F2 Steering column/steering wheel R2 Rear frame section
F3 Pedals S1 Left-hand door
K250 (280) Relay, reversing light
F4 Front wall inside left S2 Right-hand door
X1544 Plug connection, frame III F5 Front wall inside right
X1627 Plug connection, reversing light
X1644 Earthing point, cab, next to central electrical system
I
X1693 Crimped connector, line 60028 Reversing light
X1834 Crimped connector, line 71300
X1968 Plug connection, cruise control switch
X2002 Plug connection, B-pillar, preselector
X2542 (246) Potential distributor, 21-pole, line 58000

T 74 6.20 - 4
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Diagram no. 81.99192.2993 Sheet 2 of 2

T 74 6.20 - 5
 WIRING DIAGRAMS

T 74 6.21 - 1
 WIRING DIAGRAMS

Gearbox, AS-TRONIC (16-SPEED) (TG-A)

Codes for installation positions
Key
Diagram no. 81.99192.2992 Sheet 1 of 2 A Rear of vehicle F6 Driver’s seat
Modification status: 04.01 B1 Engine F7 Co-driver’s seat
B2 Gearbox F8 Gearshift console
A = Voltage supply
B = Diagnosis C Front of vehicle G Battery box
C = Gear indicator, check lamp C1 Bumper H1 B-pillar, driver's side
C2 Right-hand entry point H2 A-pillar, driver's side
A100 (255) Central electrical system
A302 (352) Central computer 2
C3 Left-hand entry point J1 B-pillar, co-driver's side
A330 (442) Control unit, AS-TRONIC (on gearbox) E6 Area of central electrical system J2 A-pillar, co-driver's side
A407 (342) Instrumentation E7 Control unit plug-in modules L Ceiling/roof
E8 Back wall of cab N Front axle
F154 (118) Fuse, gearbox (terminal 15)
F196 (118) Fuse, gearbox (terminal 30)
F Instrument panel P Rear axle
F1 Mid-section R1 Front frame section
H179 Check lamp, gearbox, status monitor F2 Steering column/steering wheel R2 Rear frame section
F3 Pedals S1 Left-hand door
P122 Gear indicator
F4 Front wall inside left S2 Right-hand door
X1553 Plug connection, engine/EDC/gearbox III F5 Front wall inside right
X1904 Threaded pin M6 (engine power box)
X1948 Plug connection, engine/gearbox (engine power box)
X2544 (246) Potential distributor, 21-pole, K-line

T 74 6.21 - 2
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Diagram no. 81.99192.2992 Sheet 1 of 2

T 74 6.21 - 3
 WIRING DIAGRAMS

Gearbox, AS-TRONIC (16-SPEED) (TG-A)

Codes for installation positions
Key
Diagram no. 81.99192.2992 Sheet 2 of 2 A Rear of vehicle F6 Driver’s seat
Modification status: 04.01 B1 Engine F7 Co-driver’s seat
B2 Gearbox F8 Gearshift console
A = Gear select, cruise control
B = Mode select C Front of vehicle G Battery box
C = Control circuit, reversing light C1 Bumper H1 B-pillar, driver's side
C2 Right-hand entry point H2 A-pillar, driver's side
A100 (255) Central electrical system
A302 (352) Central computer 2
C3 Left-hand entry point J1 B-pillar, co-driver's side
A403 (339) Vehicle management computer E6 Area of central electrical system J2 A-pillar, co-driver's side
A429 (401) Steering column stalk, cruise control/gearbox E7 Control unit plug-in modules L Ceiling/roof
A434 (402) Mode switch, gearbox E8 Back wall of cab N Front axle
F314 (101) Fuse, reversing light
F Instrument panel P Rear axle
F1 Mid-section R1 Front frame section
H378 Check lamp, RSG/RSL (LED) F2 Steering column/steering wheel R2 Rear frame section
F3 Pedals S1 Left-hand door
K250 (280) Relay, reversing light
F4 Front wall inside left S2 Right-hand door
X1544 Plug connection, frame III F5 Front wall inside right
X1627 Plug connection, reversing light
X1644 Earthing point, cab, next to central electrical system
X1693 Crimped connector, line 60028 I Reversing light
X1834 Crimped connector, line 71300
X1968 Plug connection, cruise control switch
X2002 Plug connection, B-pillar, preselector
X2542 (246) Potential distributor, 21-pole, line 58000

T 74 6.21 - 4
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Diagram no. 81.99192.2992 Sheet 2 of 2

T 74 6.21 - 5
 WIRING DIAGRAMS

T 74 6.22 - 1
 WIRING DIAGRAMS

Drive module, AS-Tronic (R02/R03)

Codes for installation positions
Key
Diagram no. 81.99289.5769 Sheet 1 of 1 A Rear of vehicle F Instrument panel
Modification status: 08.00 B Engine, gearbox G Battery box (front)
C Front of vehicle G1 Battery box (rear)
A = Voltage supply, gearbox control
B = Diagnosis D Main switchboard H Left-hand side of vehicle
C = T-CAN interface E Equipment compartment (battery box) J Right-hand side of vehicle
E1 Equipment board 1 (sec. switchboard) K Middle of vehicle
A100 (255) Central electrical system E6 Area of central electrical system (CES) L Ceiling
A302 (352) Central computer 2
A330 (442) Control unit, AS-TRONIC (on gearbox) E7 Control unit plug-in modules N Front axle
P Rear axle
F154 (118) Fuse, gearbox (terminal 15)
F196 (118) Fuse, gearbox (terminal 30)

X1904 Threaded pin M6 (engine power box)

X1948 Plug connection, engine/gearbox (engine power box)
X2041 Plug connection, adaptation, AS-TRONIC
X2042 Plug connection, adaptation, AS-TRONIC I Diagnosis, K-line (series standard wiring diagram, basic vehicle)
X2043 Plug connection, adaptation, AS-TRONIC
X2303 Plug connection, oil level sensor/drive module
X2304 Plug connection, gearbox/retarder, drive module

T 74 6.22 - 2
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Diagram no. 81.99289.5769 Sheet 1 of 1

T 74 6.22 - 3
 WIRING DIAGRAMS

T 74 6.23 - 1
 WIRING DIAGRAMS

AS-Tronic (R02/R03)
Codes for installation positions
Key
Diagram no. 81.99289.5810 Sheet 1 of 2 A Rear of vehicle F Instrument panel
Modification status: 09.01 B Engine, gearbox G Battery box (front)
C Front of vehicle G1 Battery box (rear)
A = Voltage supply, AS-Tronic gearbox
B = Diagnosis, AS-Tronic D Main switchboard H Left-hand side of vehicle
C = Buzzer, gear E Equipment compartment (battery box) J Right-hand side of vehicle
E1 Equipment board 1 (sec. switchboard) K Middle of vehicle
A100 (255) Central electrical system E6 Area of central electrical system (CES) L Ceiling
A302 (352) Central computer 2
A330 (442) Control unit, AS-TRONIC (on gearbox) E7 Control unit plug-in modules N Front axle
A413 (280) Multiplex node, front, control units 1.3 P Rear axle

F154 (101) Fuse, gearbox (terminal 15)

F196 (101) Fuse, gearbox (terminal 30)

X1553 Plug connection, engine/EDC/gearbox III

X1904 Threaded pin M6 (engine power box)
X1948 Plug connection, engine/gearbox (engine power box) I Series standard wiring diagram, basic vehicle
X2304 Plug connection, gearbox/retarder, drive module

T 74 6.23 - 2
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Diagram no. 81.99289.5810 Sheet 1 of 2

T 74 6.23 - 3
 WIRING DIAGRAMS

AS-Tronic (R02/R03)
Codes for installation positions
Key
Diagram no. 81.99289.5810 Sheet 2 of 2 A Rear of vehicle F Instrument panel
Modification status: 10.00 B Engine, gearbox G Battery box (front)
C Front of vehicle G1 Battery box (rear)
A = Gear select, cruise control
B = Mode switch, gearbox D Main switchboard H Left-hand side of vehicle
E Equipment compartment (battery box) J Right-hand side of vehicle
A100 (255) Central electrical system E1 Equipment board 1 (sec. switchboard) K Middle of vehicle
A302 (352) Central computer 2
A403 (339) Vehicle management computer
E6 Area of central electrical system (CES) L Ceiling
A407 (342) Instrumentation E7 Control unit plug-in modules N Front axle
A429 (401) Steering column stalk, cruise control/gearbox P Rear axle
A434 (402) Mode switch, gearbox

H179 Check lamp, gearbox, status monitor

H378 Check lamp, RSG/RSL (LED)

P122 Gear indicator

I Additional wiring diagram, voltage supply
X618 (128) Distributor, terminal board X102, line 31000
X633 Plug connection, gear selector switch II Additional wiring diagram, vehicle management computer
X1081 Plug connection to cruise control switch
X1968 Plug connection, cruise control switch
X3100 Plug connection, vehicle management computer – main
switchboard

T 74 6.23 - 4
 WIRING DIAGRAMS
Diagram no. 81.99289.5810 Sheet 2 of 2

T 74 6.23 - 5
 DIAGNOSIS

Diagnosis socket (X200)

The SPN fault codes can be read out 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

8 1
7 9 2
12 10
6 11 3
5 4

Central arrow
points towards pin 1

Connector pin assignment

− TG-A:

Diagnosis socket X200 Address

Pin Function Terminal Line number From CES pin

4 K-line 16202 Via X2544 to the control units

KWP 2000
9 Negative 31 31000 Earthing point, central
potential electrical system
X1644 via X1829
10 Voltage supply 30 30009 Via X1535 to fuse F412 / 10A A2/11
11 Voltage supply 15 16000 Via X1833 to fuse F376 / 10A F/3
12 Signal, alternator W 59101 Alternator G102 pin 1

− R02/R03:

Diagnosis socket X200 Address

Pin Function Terminal Line number From CES pin

4 K-line 16202 Via X1908 to the control units

KWP 2000
9 Negative 31 31000 Earthing point, central
potential electrical system (item 92)
10 Voltage supply 30 30009 Fuse F412 / 10A A2/11
11 Voltage supply 15 16000 Via X362 to fuse F/3
F376 / 10A
12 Signal, alternator W 59101 Alternator G102 pin 1

T 74 8.03 - 1
DIAGNOSIS

Installation position
1
TG-A:

The diagnosis socket 1 is located on the rear side of

the central electrical system.

R02/R03:

The diagnosis socket 1 is located on the left under

1
the driver's seat.

8.03 - 2 T 74
 DIAGNOSIS

Fault code

The main functions of diagnosis are:

− Fault detection
− Fault analysis
Occurrence
Meaning
Identification
Fault type (static, sporadic, ...)
− Fault saving
− Simulation for troubleshooting

Malfunction indicators

The electronic gearbox control has self-diagnosis functions for all outputs and various inputs. The faults at
the inputs and outputs, as well as internal faults, are detected, analysed and stored.

The faults are also indicated on the instrument panel display and/or by the central warning light (H111) in
conjunction with the gearbox status monitor check lamp (H179).
In the case of STOP warnings, the word STOP also appears on the display and the central warning light
(H111) flashes RED at 1-second intervals.

The central warning light (H111) lights up:

− YELLOW to indicate either a function or a warning
− RED to indicate a fault

Red always has priority over yellow. Functions or warnings (YELLOW) are always overridden by faults
(RED).
The gearbox status monitor check lamp (H179) always lights up RED.
Faults are indicated by the central warning light (H111) and supporting display message.

In the event of a CAN failure (instrumentation – central on-board computer),the central warning light (H111)
lights up RED.

All current malfunction indicators are available when the ignition is switched ON (terminal 15), irrespective
of the vehicle status.

The faults diagnosed and stored in the control unit may involve different risks. Therefore, each individual
fault is assigned a priority.

Indicator priorities

The display can not show all the information at once. It therefore shows information according to priorities.
Lower-priority information can be overwritten by higher-priority information.

Pieces of information that have the same priority are shown alternately if there is not enough room on the
display.

Diagnosis requires priorities 1 – 5.

Some function indicators have the same or a higher priority than fault indicators. In other words, a
function indicator (YELLOW) can have the same priority as a RED fault or even a STOP fault.

If the display area is already full and additional function indicators and fault indicators with the same
priority occur, the function indicator is given priority.

T 74 8.10 - 1
DIAGNOSIS

Indicator/diagnosis priorities

Diagnosis Indicator Colour of central Diagnosis

priority meaning warning light (H111) meaning
1 Indicator critical to RED flashing Drivability or safety is endangered
safety (STOP fault, RED)
2 Indicator critical to RED steady light Driving information with
functioning recommended action, check
(RED fault)
3 Indicator not necessary YELLOW steady light Information before starting to drive
for purely normal or active safety not restricted
operation (YELLOW fault)
4 --- --- No effect on drivability
5 Information about fault YELLOW steady light Warning (YELLOW fault)
whilst vehicle in motion

The display only ever shows one fault at a time.

Structure of fault texts in diagnostic message

There are 2 lines of 16 characters available for the fault texts in the diagnostic message.

The fault text message structure always includes

− Fault location/fault designation
− Fault information/recommended action

There are 2 types of fault text messages:

− Global fault text messages
− Concrete fault text messages

Global fault text message

In the global fault text message, only the priority and the source address from the DM1 message
(diagnosis message 1) are evaluated. A general message is displayed, indicating the defective system
and the transmitted fault number.

Diagnosis Central Fault text Remarks

priority warning light 1234567890123456
1 RED flashing Sysname no. xxxxx-yy In conjunction with STOP symbol.
Diagnosis Engine must be stopped!
2 RED steady Sysname no. xxxxx-yy Possibly workshop-relevant fault!
light Diagnosis Indicates malfunction
3 YELLOW Sysname no. xxxxx-yy Display at standstill, fault info. only;
steady light Diagnosis no recommended action necessary
4 --- --- No display
5 YELLOW Sysname no. xxxxx-yy Display when vehicle in motion and at
steady light Diagnosis standstill; fault info. only

− "Sysname": Indicates the defective system from the source address of DM1 (e.g.: TCU)
− "xxxxx": Indicates fault number (03003) from fault location number SPN in DM1 message

SPN --> Suspect Parameter Number (fault location)

8.10 - 2 T 74
 DIAGNOSIS

Concrete fault text message

In the case of the concrete fault text message, the priority, SPN fault number and fault type (FMI)
transmitted in the DM1 message are also evaluated. There is concrete recommended action and concrete
naming of the fault cause.
The SPN fault number is not displayed in the case of concrete fault text messages. The concrete fault text
message is triggered when the source address of the DM1 message "Onboard Diagnostic Unit" is
indicated.

Diagnosis Central Fault text Remarks

priority warning light 1234567890123456
1 RED flashing Sysname no. xxxxx-yy In conjunction with STOP symbol.
Diagnosis Engine must be stopped!
2 RED steady Sysname no. xxxxx-yy Possibly workshop-relevant fault!
light Diagnosis Indicates malfunction
3 YELLOW Sysname no. xxxxx-yy Display at standstill, fault info. only;
steady light Diagnosis no recommended action necessary
4 --- --- No display
5 YELLOW Sysname no. xxxxx-yy Display when vehicle in motion and at
steady light Diagnosis standstill; fault info. only

− "Sysname": Indicates the defective system from the source address of DM1 (e.g.: TCU)
− "xxxxx": Indicates the fault number from the fault location number (SPN) in the DM1 message
(e.g.: TCU no. 03003)
− "yy": Indicates the fault type number (FMI) (e.g.: TCU no. 03003-05)

SPN --> Suspect Parameter Number (fault location)

FMI --> Failure Mode Identification (fault type)

Note: Several different faults can trigger the same concrete fault text message.

Emergency functions

The electronic control unit (A330) receives various pieces of information via the "drive train" CAN databus
(T-CAN).
The control units transmit a send message address for this purpose. These send message addresses can
be assigned to the control units.
In the event of a fault in the electronic gearbox control, that only permits restricted operation of the
gearbox system, "Automatic" mode is shut off and the system switches to "Manual" mode. The main
thinking behind this is that, in exceptional circumstances, the timing of a gear change and the choice of
gear should be left up to the driver.
In exceptional circumstances, the driver is better able to correctly assess the overall situation and react
accordingly. This is why the shift strategy is always deactivated when the gearbox switches to emergency
mode.

If the steering column stalk (A429) fails, the vehicle management computer (A403) detects that the
steering column stalk is not working. Automatic mode is activated in the electronic control unit (A330).

If the mode switch (A434) fails, the vehicle management computer (A403) detects that the mode switch is
not working. The AS-Tronic is then operated using the steering column stalk (A429).
If this fault occurs, the driver must use the steering column stalk (A429) to change from a forward gear to
a reverse gear via neutral and vice versa.

T 74 8.10 - 3
DIAGNOSIS

Timeout error
All CAN databus stations monitor the messages that need to be periodically sent and, if this receive
message is missing, internally enter a corresponding timeout error code in their respective error
memories.
Timeout monitoring is active in drive mode (terminal 15 and terminal 30 energised).

Busoff error
If the "busoff" error state occurs, all CAN databus stations enter this in their error memories as an error
code.
Busoff monitoring is active in drive mode (terminal 15 and terminal 30 energised).

EOL programming and diagnosis

It must still be possible to send CAN messages during EOL programming or control unit diagnosis.
The control unit concerned continues sending its messages in these phases; however, the message
content can be set to "Signal not available" or "not active".

After-run mode
During engine after-run (terminal 15 deactivated), it may be necessary for certain after-running control
units to exchange messages. The electronic diesel control (EDC) also maintains CAN communication in
after-run mode; however, EDC performs no error monitoring and makes no error entries whatsoever.
Other CAN databus stations, the control units of which are energised in the after-run phase, are also not
permitted to perform error monitoring (timeout, busoff,...) on the CAN interface and may only set the
sending and receiving of CAN messages after the electronic diesel control (EDC) has sent engine speed
= 0 at the latest.

8.10 - 4 T 74
 DIAGNOSIS

On-board diagnosis

Fault indication on request (Baseline instrumentation)

Faults present can be read out on the driver's display using the menu structure from the main "Diagnosis"
menu.

Check whether there is a fault indicated:

The menu structure is controlled using buttons 1 and 2 .

There are two ways of using the buttons:
PRESSING and TOUCHING
− PRESSING – press and hold (for more than
3 seconds), e.g. to call up the menu or to confirm.
− TOUCHING – briefly press (for less than 2 seconds),
e.g. to scroll through the menu or to exit the menu.

The functions performed by button 1 are indicated by

left-hand icon 3 whilst those performed by button 2 are
indicated by right-hand icon 4 on the driver's display.

MENU
How to access the menu structure: Press button 1

(>3 sec): VEHICLE CONFIG.

Various menus are available, depending on the vehicle OPERATING DATA
operating state:
DIAGNOSIS
Operating state Available main menus
Ignition on VEHICLE CONFIG.
Vehicle stationary OPERATING DATA
Engine off DIAGNOSIS
LAMP TEST
MAINTENANCE
1ST REGISTERED
TRAILER CONFIG.
Ignition on
Vehicle stationary OPERATING DATA
Engine on

Press button 1 (<2 sec) to switch from a main menu to another menu.
Press button 2 (<2 sec) to access the submenus in the current main menu.

Main menu display (depending on the vehicle operating state):

VEHICLE OPERATING 1ST TRAILER

DIAGNOSIS LAMP TEST MAINTENANCE
CONFIG. DATA REGISTERED CONFIG

Button 2 Button 2 Button 2 Button 2 Button 2 Button 2 Button 2

Submenu Submenu Submenu Submenu Submenu Submenu Submenu

T 74 8.10 - 5
DIAGNOSIS

The "DIAGNOSIS" main menu contains further submenus, the number of which depends on how many
systems are installed in the vehicle (e.g. ZBR, EBS, ECAM, EDC, FFR, DIAG, ECAS, RET S, TCU, INST).
These submenus display the content of the relevant fault memory.

Ignition on

Button 3>3 sec MENU

OPERATING DATA
Button 3<2 sec >DIAGNOSIS
LAMP TEST
ê è

Button 4<2 sec

DIAGNOSIS
>ZBR
EBS
ECAM
ê è

Button 3<2 sec Button 4<2 sec

DIAGNOSIS
EBS ZBR fault!
>ECAM Code ê OK
EDC
ê è
Button 4<2 sec
Button 3<2 sec Button 4<2 sec

DIAGNOSIS
INST ECAM fault!
>------------- Code ê OK
ë OK
Button 4<2 sec
Button 3<2 sec Button 4<2 sec

8.10 - 6 T 74
 DIAGNOSIS

Fault indication on request (Highline instrumentation)

Faults present can be read out on the driver's display using the vehicle menu from the main "Diagnosis"
menu.

Vehicle menu button 1

− Press to call up the vehicle menu
3 4
Rotary/pressure switch button 2 1
− Turn (anti-clockwise/clockwise) to select menu item
− Press to call up a menu item

Previous menu button 3

− Press to exit a menu item
2
Exit menu button 4
− Press to exit the selected menu
(e.g. diagnosis).

Calling up the "Diagnosis" vehicle menu

Check whether there is a fault indicated:

The "Diagnosis" vehicle menu is called up when the

vehicle is stationary.
− Press the "Vehicle menu" button 1 until the vehicle
Vehicle menu
menu appears on the driver's display (Instr. config., Instr. config.
Trip data, Operating data, Vehicle config., Trip data
Maintenance ....). Operating data
The 1st menu item ("Instr. config.") is marked.
Vehicle config.
Maintenance

− Turn the rotary/pressure-operated switch 2 and

select the "Diagnosis" menu item 5 .
The selected menu item is marked with a bar.
− Press rotary/pressure-operated switch, call up
"Diagnosis".
Vehicle menu
Note: Pressing the "Previous menu" button 3
enables you to leave the menu item you have Trip data
just selected without leaving the vehicle Operating data
menu. Vehicle config.
Maintenance
Leaving the vehicle menu 5
− Press the "Exit menu" button 4 .
Diagnosis

The "DIAGNOSIS" main menu contains further submenus, the number of which depends on how many
systems are installed in the vehicle (e.g. ZBR, EBS, ECAM, EDC, FFR, DIAG, ECAS, RET S, TCU, INST).
These submenus display the content of the relevant fault memory.

T 74 8.10 - 7
DIAGNOSIS

The table below explains what the abbreviations used in the submenus mean.

Abbreviations Meaning
ZBR Central on-board computer 2
EBS Electronic brake system
ECAM Electronically controlled air management
EDC Electronic diesel control
FFR Vehicle management computer
DIAG Entire vehicle (on-board diagnosis memory)
ECAS Electronically controlled air suspension
RET S Retarder/Intarder, secondary
TCU Transmission control unit (automated/automatic gearbox)
INST Instrumentation
ACC Adaptive cruise control
KSM Customer-specified module
M-TCO Tachograph

If buttons 1 or 2 are not pressed within a certain time (approx. 30 seconds), the menu structure
disappears automatically and is replaced by the display that appeared before the menu structure was
accessed.

SPN – fault code list

The following table lists the fault codes that can be read out via diagnosis socket X200 using the MAN-cats
diagnosis system in the event of a fault (SPN – Suspect Parameter Number – fault location).
Address: 18 Control unit, AS-Tronic

SPN Address SPN plain text

03002 18 Y2 valve, splitter low
03003 18 Y3 valve, splitter high
03004 18 Y4 valve, gate position 3/4
03005 18 Y5 valve, gate position 1/2
03006 18 Y6 valve, shift position 1/R
03007 18 Y3 valve, shift position 2/3
03008 18 Y3 valve, range-change group low
03009 18 Y3 valve, range-change group high
03010 18 Y10, main valve
03017 18 Y1, transmission brake
03018 18 Small valve for opening the clutch
03019 18 Small valve for closing the clutch
03020 18 Large valve for opening the clutch
03021 18 Large valve for closing the clutch
03022 18 Voltage supply, speed sensor, ASTronic, output
03026 18 CAN databus, engine configuration from EDC, engine configuration
03027 18 CAN databus, engine configuration from EDC, engine configuration
03028 18 CAN databus, retarder check from secondary retarder, ERC1_RD
(current/actual retarder torque)
03029 18 CAN databus, retarder check from secondary retarder, ERC1
(additional heating of engine, engine coolant load increase)

8.10 - 8 T 74
 DIAGNOSIS

SPN – fault code list

SPN Address SPN plain text

03030 18 CAN databus, retarder configuration from secondary retarder,
Ret_Conf driveline retarder configuration
03031 18 CAN databus, retarder check from vehicle management computer
engine brake torque, "ERC1_ REX retarder percent torque"
03032 18 CAN databus, engine brake configuration, "engine retarder
configuration"
03033 18 CAN databus, engine brake configuration, "engine retarder configuration"
03049 18 Y1, transmission brake
03050 18 Small valve for opening the clutch
03051 18 Small valve for closing the clutch
03052 18 Large valve for opening the clutch
03053 18 Large valve for closing the clutch
03059 18 Feedback, power take-off 1
03060 18 Feedback, power take-off 2
03061 18 Deactivation, power take-off 1
03062 18 Deactivation, power take-off 2
03063 18 Activation, power take-off 1
03064 18 Activation, power take-off 2
03090 18 ECU (communication, controllers 1 + 2)
03091 18 CAN databus EBS1 from EBS, EBC1
03099 18 Output speed 1
03101 18 Output speed 1 + 2
03102 18 Gearbox input and output speed
03103 18 CAN databus, vehicle speed from EDC
03107 18 Voltage (clutch sensor)
03111 18 CAN databus, time/date information from ZBR2, TIME/DATE
03112 18 CAN databus, time/date information from ZBR2, TIME/DATE
03113 18 CAN databus, retarder configuration, "Ret_Conf"
(driveline retarder configuration)
03117 18 Self adjustment, clutch, defective
03118 18 Clutch does not open
03119 18 Clutch does not close/does not transmit torque
03120 18 Mechanical fault (small valve for opening the clutch)
03121 18 Mechanical fault (small valve for closing the clutch)
03122 18 Mechanical fault (large valve for opening the clutch)
03123 18 Mechanical fault (large valve for closing the clutch)
03124 18 Fault, clutch travel
03125 18 Fault, pressure limiting valve
03126 18 Pressure signal defective
03127 18 Fault, ECU temperature
03128 18 Fault, signal, oil temperature
03129 18 No signal from shift sensor
03132 18 Fault, self-adjustment, shift sensor
03133 18 Gate selection sensor signal
03136 18 Programming error, gate selection sensor signal
03137 18 Position sensor signal, range-change group
03140 18 Programming error, position sensor, range-change group
03141 18 No position sensor signal, splitter

T 74 8.10 - 9
DIAGNOSIS

SPN – fault code list

SPN Address SPN plain text

03144 18 Fault, position sensor signal, splitter, self-adjustment
03145 18 Range-change group does not disengage
03146 18 Changeover fault in event of range-change group fault
03147 18 Range-change group does not engage
03148 18 Splitter does not disengage
03149 18 Changeover fault, splitter shift
03150 18 Splitter group does not engage
03151 18 Selector cylinder does not open
03152 18 Fault, shift, gate
03153 18 Selector cylinder does not close
03154 18 Main gearbox gear does not disengage
03155 18 Main gearbox gear does not engage
03156 18 Wrong gear engaged
03158 18 Shift sensor signal continuously active
03159 18 Range-change group shift sensor signal continuously active
03160 18 Splitter shift sensor signal continuously active
03163 18 Engine does not react to torque specification
03164 18 CAN databus, electronic engine control 1 from EDC, EEC1
(accelerator pedal position, drivers demand engine percent torque)
03166 18 Permanent idling speed signal
03169 18 Shut-off relay in ECU does not switch off
03170 18 No voltage supply at terminal 30 or shut-off relay in ECU not activated
03171 18 CAN databus electronic engine control 1 from EDC, EEC1
(engine torque, actual engine percent torque)
03175 18 Fault, signal, ignition lock (terminal 15)
03177 18 CAN databus, drive train
03179 18 CAN databus, input buffer overrun
03180 18 CAN databus, electronic engine control 1 from EDC, EEC1
03181 18 CAN databus, electronic engine control 2 from EDC, EEC2
03182 18 CAN databus, cruise control/speed from EDC, CCVS
03183 18 CAN databus, engine brake from vehicle management computer,
ERC1_REX
03184 18 CAN databus, retarder from secondary retarder, ERC1_RD
03188 18 Control units, fault, incorrect interrupt
03189 18 Control units, fault, stack watch
03190 18 EOL, EEPROM, parameters outside valid range
03191 18 EOL EEPROM: checksum error
03192 18 Control units, fault – EEPROM access error
03193 18 ECU, temperature too high
03196 18 CAN databus, vehicle mileage from ZBR2, Veh_Dist
03198 18 CAN databus, relative wheel speed from EBS, EBC2 (WSI) (relative
wheel speed)
03199 18 CAN databus, wheel speed information from EBS, EBC2 (WSI)
03210 18 CAN databus, tachograph from ZBR2, TCO1
03211 18 CAN databus gearbox check from vehicle management computer,
TC1_FT
03212 18 CAN databus, gearbox check from vehicle management computer,
TC1_FT (requested gear)

8.10 - 10 T 74
 DIAGNOSIS

SPN – fault code list

SPN Address SPN plain text

03213 18 CAN databus, gearbox check from vehicle management computer,
TC1_FT (requested range)
03214 18 CAN databus, gearbox check from vehicle management computer,
TC1_FT (PTO request)
03209 18 CAN databus, information from ZBR (aux_stat_zbr#1)
03215 18 EMERGENCY OFF switch actuated

Address directories

Address Control unit Address Control unit

1 CRT 38 ECAS/EFR
10 EDC 61 Instrumentation
14 EDC 7 Master 98 GKR air conditioning
15 EDC 7 Slave 9A T50 / AT 3500
18 AS-Tronic 9A D5W SC
19 WSK 9C AT 3500
20 FFR 9C D1LC/D3LC
21 ZBR 2 a8 Door module, driver's seat
22 ECAM a9 Door module, co-driver's seat
2a EBS c2 Airbag
2c WaPu DO KSM
2d Intarder E8 LGS
31 RAS-EC1 fb ZBR 2 OBDU

T 74 8.10 - 11
 DIAGNOSIS

SPN – fault code description

The following fault code descriptions document the fault reactions when the vehicle is in motion and at a
standstill.

SPN --> Suspect Parameter Number (fault location)

FMI --> Failure Mode Identification (fault type)

SPN Display Description FMI Reaction when vehicle in motion/at standstill

00028 STOP symbol Accelerator pedal 3 In motion: Gear shifts blocked
Buzzer, position out of valid At standstill: Automatic shift to neutral, gear shifts
warning light range blocked, continued driving not possible
00158 No display Overvoltage (vehicle 1 No restrictions in the system
voltage too high)
00158 Buzzer, Undervoltage: 2 In motion: Gear "frozen"
warning light Terminal 15, not At standstill: Automatic shift to neutral, gear shifts
enough voltage or no blocked, continued driving not possible
voltage Note: Check automatic cut-out, replace with fuse
if necessary
00161 Buzzer, No gearbox input 8 In motion: Longer shift time
warning light speed/gearbox input At standstill: Longer shift time. Deterioration in
speed fault clutch engagement quality when manoeuvring
and starting off.
Note: Gearbox can only be shifted manually
00168 STOP symbol No voltage supply at 9 In motion: Gear "frozen"
Buzzer, terminal 30 or cut-off At standstill: Automatic shift to neutral, gear shifts
warning light relay in ECU not blocked, continued driving not possible
deactivated Note: Check automatic cut-out, replace with fuse
if necessary
00190 Buzzer, No engine speed/ 8 In motion: Clutch time-controlled during shift
warning light speed fault At standstill: Clutch time-controlled when starting
off, deterioration in clutch engagement quality
when manoeuvring and starting off
Note: Gearbox can only be shifted manually
00191 STOP symbol Fault, gearbox output 8 In motion: Clutch time-controlled during shift
Buzzer, speed, speedo, At standstill: Clutch time-controlled when starting
warning light speed fault, output off, deterioration in clutch engagement quality
speed sensor_2 when manoeuvring and starting off
(speedo) Note: Gearbox can only be shifted manually. Fault
frequently set without effect in the case of
software 2.1.
00629 STOP symbol Communications 9 In motion: Gear shift blocked
Buzzer, fault between At standstill: Automatic shift to neutral, gear shifts
warning light Controller 1 and blocked, continued driving not possible
Controller 2
(ECU fault)

T 74 8.11 - 1
DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

00639 STOP symbol CAN Busoff, 4 In motion: Gear shift blocked
Buzzer, interrupt At standstill: Automatic shift to neutral, gear shifts
warning light blocked, continued driving not possible
01043 STOP symbol Interrupt at output 1 In motion: Clutch time-controlled during shift
Buzzer, ADVP (voltage At standstill: Clutch time-controlled when starting
warning light supply, output off, deterioration in clutch engagement quality
sensor 1) when manoeuvring and starting off
Note: Gearbox can only be shifted manually
03002 STOP symbol Short-circuit, ground 5 In motion: Gear shift blocked
Buzzer, (valveY2) GV DD: At standstill: Automatic shift to neutral, gear shifts
warning light High, OD: (Low) blocked, continued driving not possible
03003 STOP symbol Short-circuit, ground 5 In motion: Gear shift blocked
Buzzer, at output AD3 to Y3 At standstill: Automatic shift to neutral, gear shifts
warning light (valve GV DD: Low, blocked, continued driving not possible
OD: High)
03004 STOP symbol Short-circuit, ground 5 In motion: Gear shift blocked
Buzzer, at output AD4 to Y4 At standstill: Automatic shift to neutral, gear shifts
warning light (valve, select 3/4, blocked, continued driving not possible
gate)
03005 STOP symbol Short-circuit, ground 5 In motion: Gear shift blocked
Buzzer, at output AD5 to Y5 At standstill: Automatic shift to neutral, gear shifts
warning light (valve, select 1/2, blocked, continued driving not possible
gate)
03006 STOP symbol Short-circuit, ground 5 In motion: Gear shift blocked
Buzzer, at output AD6 to Y6 At standstill: Automatic shift to neutral, gear shifts
warning light (valve, shift 1/3, blocked, continued driving not possible
gear)
03007 STOP symbol Short-circuit, ground 5 In motion: Gear shift blocked
Buzzer, at output AD7 to Y7 At standstill: Automatic shift to neutral, gear shifts
warning light (valve, shift 2/4, blocked, continued driving not possible
gear)
03008 STOP symbol Short-circuit, ground 5 In motion: Gear shift blocked
Buzzer, at output AD8 to Y8 At standstill: Automatic shift to neutral, gear shifts
warning light (valve, range-change blocked, continued driving not possible
group, low, GP)
03009 STOP symbol Short-circuit, ground 5 In motion: Gear shift blocked
Buzzer, at output AD9 to Y9 At standstill: Automatic shift to neutral, gear shifts
warning light (valve, range-change blocked, continued driving not possible
group, high, GP)
03010 STOP symbol Short-circuit, ground 5 In motion: No gear shifts possible, no neutral
Buzzer, at output AD10 to possible, selected gear remains engaged
warning light Y10 (main valve) At standstill: System not available
03017 STOP symbol Short-circuit, ground 5 In motion: Upshifts are treated as downshifts,
Buzzer, at output ADS1 to Y1 input speed synchronised by engine speed
warning light (transmission brake Upshifts are blocked if the target speed is less
valve) than the engine speed

8.11 - 2 T 74
 DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03018 Buzzer, Short-circuit, ground 5 Automatic deactivation of ECU
warning light at output ADS2 Y17 Function taken over by large opening valve,
to small clutch valve deterioration in manoeuvring and starting-off
"open" quality
03019 Buzzer, Short-circuit, ground 5 Automatic deactivation of ECU
warning light at output ADS3 Y15 Function taken over by large closing valve,
to small clutch valve deterioration in manoeuvring and starting-off
"close" quality
03020 Buzzer, Short-circuit, ground 5 Automatic deactivation of ECU
warning light at output ADS4 Y16 Function taken over by small opening valve,
to large clutch valve longer shift time; deterioration in starting-off
"open" quality
03021 Buzzer, Short-circuit, ground 5 Automatic deactivation of ECU
warning light at output ADS5 Y14 Function taken over by small closing valve,
to large clutch valve deterioration in clutch engagement quality after
"close" shift, deterioration in manoeuvring and starting-off
quality
03022 STOP symbol Short-circuit, ground 5 In motion: Clutch time-controlled during shift
Buzzer, at output ADVP At standstill: Clutch time-controlled when starting
warning light (voltage supply and off, deterioration in clutch engagement quality
to output, output when manoeuvring and starting off
sensor) Note: Gearbox can only be shifted manually, Kitas
redundant signal used
03026 CAN Engine configuration, EDC Timeout
databus In motion: Applied default parameters taken from
error application characteristics. Reduced functionality
for automatic mode and starting gear calculation if
difference between the default parameters and
the actual values is too great.
03027 CAN Engine configuration, EDC.
databus In motion: Applied default parameters taken from
error application characteristics. Reduced functionality
for automatic mode and starting gear calculation if
difference between the default parameters and
the actual values is too great.
Note: Error frequently set without effect in the
case of FFR 7003
03028 CAN Retarder check (current retarder torque)
databus In motion: No calculation of driving resistance, no
error automatic calculation of starting gear. Medium
starting gear is engaged when vehicle comes to a
standstill.
03029 CAN Retarder check (additional heating of the engine)
databus In motion: There are no downshift requests from
error the retarder – in order to increase the engine
speed to improve the cooling capacity.
03030 CAN Retarder check
databus In motion: No calculation of driving resistance, no
error automatic calculation of starting gear. Medium
starting gear is engaged when vehicle comes to a
standstill.

T 74 8.11 - 3
DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03031 CAN Retarder check, FFR, engine brake torque
databus In motion: No calculation of driving resistance, no
error automatic calculation of starting gear. Medium
starting gear is engaged when vehicle comes to a
standstill.
03032 CAN Engine brake configuration
databus In motion: No calculation of driving resistance, no
error automatic calculation of starting gear. Medium
starting gear is engaged when vehicle comes to a
standstill.
03033 CAN Engine brake configuration, Timeout
databus In motion: No calculation of driving resistance, no
error automatic calculation of starting gear. Medium
starting gear is engaged when vehicle comes to a
standstill.
03034 STOP symbol Interrupt at output 1 In motion: Gear shift blocked
or Buzzer, AD2 to Y2 split At standstill: Automatic shift to neutral, gear shifts
03002 warning light (valve GV DD: High, blocked, continued driving not possible
OD: Low)
03035 STOP symbol Interrupt at output 1 In motion: Gear shift blocked
or Buzzer, AD3 to Y3 split At standstill: Automatic shift to neutral, gear shifts
03003 warning light (valve GV DD: Low; blocked, continued driving not possible
OD: High)
03036 STOP symbol Interrupt at output 1 In motion: Gear shift blocked
or Buzzer, AD4 to Y4 (valve, At standstill: Automatic shift to neutral, gear shifts
03004 warning light select 3/4, gate) blocked, continued driving not possible
03037 STOP symbol Interrupt at output 1 In motion: Gear shift blocked
or Buzzer, AD5 to Y5 (valve, At standstill: Automatic shift to neutral, gear shifts
03005 warning light select 1/2, gate) blocked, continued driving not possible
03038 STOP symbol Interrupt at output 1 In motion: Gear shift blocked
or Buzzer, AD6 to Y6 (valve, At standstill: Automatic shift to neutral, gear shifts
03006 warning light shift 1/3, gear) blocked, continued driving not possible
03039 STOP symbol Interrupt at output 1 In motion: Gear shift blocked
or Buzzer, AD7 to Y7 (valve, At standstill: Automatic shift to neutral, gear shifts
03007 warning light shift 2/4, gear) blocked, continued driving not possible
03040 STOP symbol Interrupt at output 1 In motion: Gear shift blocked
or Buzzer, AD8 to Y8 (valve, At standstill: Automatic shift to neutral, gear shifts
03008 warning light range-change group, blocked, continued driving not possible
low, GP)
03041 STOP symbol Interrupt at output 1 In motion: Gear shift blocked
or Buzzer, AD9 to Y9 (valve, At standstill: Automatic shift to neutral, gear shifts
03009 warning light range-change group, blocked, continued driving not possible
high, GP)
03042 STOP symbol Interrupt at output 1 In motion: No gear shifts possible, no neutral
or Buzzer, AD10 to Y10 (main possible, selected gear remains engaged
03010 warning light valve) (4-6) At standstill: System not available

8.11 - 4 T 74
 DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03049 STOP symbol Interrupt at output 1 In motion: Upshifts are treated as downshifts,
Buzzer, ADS1 to Y1 input speed synchronised by engine speed
warning light (transmission brake Upshifts are blocked if the target speed is less
valve) than the engine speed
03050 Buzzer, Interrupt at output 1 Function taken over by large opening valve:
warning light ADS2 Y17 to small Deterioration in manoeuvring and starting-off
clutch valve "open" quality.
03051 Buzzer, Interrupt at output 1 Function taken over by large closing valve:
warning light ADS3 Y15 to small Deterioration in manoeuvring and starting-off
clutch valve "close" quality.
03052 Buzzer, Interrupt at output 1 Function taken over by small opening valve,
warning light ADS4 Y16 to large longer shift time, deterioration in starting-off
clutch valve "open" quality
03053 Buzzer, Interrupt at output 1 Function taken over by small closing valve,
warning light ADS5 Y14 to large deterioration when clutch closed after shift,
clutch valve deterioration in manoeuvring and starting-off
"close" quality
03059 Feedback, power
take-off1
03060 Feedback, power
take-off2
03061 Deactivation, power Gear shift blocked
take-off1
03062 Deactivation, power Gear shift blocked
take-off2
03063 Activation, power Power take-off not available
take-off1
03064 Activation, power Power take-off not available
take-off2
03066 STOP symbol Short-circuit, positive 6 In motion: Gear shift blocked
or Buzzer, at output AD2 to Y2 At standstill: Automatic shift to neutral, gear shifts
03002 warning light split (valve GV DD: blocked, continued driving not possible
High, OD: Low)
03067 STOP symbol Short-circuit, positive 6 In motion: Gear shift blocked
or Buzzer, at output AD3 to Y3 At standstill: Automatic shift to neutral, gear shifts
03003 warning light split (valve GV DD: blocked, continued driving not possible
Low; OD: High)
03068 STOP symbol Short-circuit, positive 6 In motion: Gear shift blocked
or Buzzer, at output AD4 to Y4 At standstill: Automatic shift to neutral, gear shifts
03004 warning light (valve, select 3/4, blocked, continued driving not possible
gate)
03069 STOP symbol Short-circuit, positive 6 In motion: Gear shift blocked
or Buzzer, at output AD5 to Y5 At standstill: Automatic shift to neutral, gear shifts
03005 warning light (valve, select 1/2, blocked, continued driving not possible
gate)
03070 STOP symbol Short-circuit, positive 6 In motion: Gear shift blocked
or Buzzer, at output AD6 to Y6 At standstill: Automatic shift to neutral, gear shifts
03006 warning light (valve, shift 1/3, blocked, continued driving not possible
gear)

T 74 8.11 - 5
DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03071 STOP symbol Positive short Y7 6 In motion: Gear shift blocked
or Buzzer, shift (2/4) At standstill: Automatic shift to neutral, gear shifts
03007 warning light Short-circuit, positive blocked, continued driving not possible
at output AD7 to Y7
(valve, shift 2/4,
gear)
03072 STOP symbol Positive short Y8 6 In motion: Gear shift blocked
or Buzzer, low GP At standstill: Automatic shift to neutral, gear shifts
03008 warning light Short-circuit, positive blocked, continued driving not possible
at output AD8 to Y8
(valve, range-change
group, low, GP)
03073 STOP symbol Short-circuit, positive 6 In motion: Gear shift blocked
or Buzzer, at output AD9 to Y9 At standstill: Automatic shift to neutral, gear shifts
03009 warning light (valve, range-change blocked, continued driving not possible
group, high, GO)
03074 STOP symbol Short-circuit, positive 6 In motion: No gear shifts possible, no neutral
or Buzzer, at output AD10 to possible, selected gear remains engaged
03010 warning light Y10 (main valve) At standstill: System not available
03081 STOP symbol Short-circuit, positive 6 In motion: Upshifts are treated as downshifts,
or Buzzer, at output ADS1 to Y1 input speed synchronised by engine speed
03017 warning light (transmission brake Upshifts are blocked if the target speed is less
valve) than the engine speed
03082 STOP symbol Short-circuit, positive 6 Function taken over by large opening valve:
or Buzzer, at output ADS2 Y17 Deterioration in manoeuvring and starting-off
03018 warning light to small clutch valve quality
"open"
03083 STOP symbol Short-circuit, positive 6 Function taken over by large closing valve:
or Buzzer, at output ADS3 Y15 Deterioration in manoeuvring and starting-off
03019 warning light to small clutch valve quality
"close"
03084 STOP symbol Short-circuit, positive 6 Function taken over by small opening valve,
or Buzzer, at output ADS4 Y16 longer shift time, deterioration in starting-off
03020 warning light to large clutch valve quality
"open"
03085 STOP symbol Short-circuit, positive 6 Function taken over by small closing valve,
or Buzzer, at output ADS5 Y14 deterioration when clutch closed after shift,
03021 warning light to large clutch valve deterioration in manoeuvring and starting-off
"close" quality
03086 Buzzer, Short-circuit, positive 6 In motion: Clutch time-controlled during shift
or warning light at output ADVP At standstill: Clutch time-controlled when starting
03022 (voltage supply, off, deterioration in clutch engagement quality
output sensor) when manoeuvring and starting off
Note: Gearbox can only be shifted manually, Kitas
redundant signal used
03090 Control unit fault,
communications,
computer 1 and 2

8.11 - 6 T 74
 DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03091 CAN databus EBC1 message from EBS, Timeout
In motion: No calculation of driving resistance, no
automatic calculation of starting gear. Medium
starting gear is engaged when vehicle comes to a
standstill.
03099 STOP symbol Speed error, output 8 Gearbox can only be shifted manually, Kitas
Buzzer, speed sensor_1 redundant signal used
warning light
03100 Speed error, output 0 No system restrictions
or sensor 2
00191 (Kitas)
03101 STOP symbol Speed error, both In motion: Gear shift blocked
Buzzer, output sensors At standstill: Automatic shift to neutral, gear shifts
warning light blocked, continued driving not possible
03102 STOP symbol Plausibility error 3 In motion: Gear shifts blocked, including attempts
Buzzer, between gearbox to shift to neutral
warning light input speed and Starting gear can be engaged, driving possible in
output speed starting gear
03103 CAN databus Vehicle speed from EDC
03106 STOP symbol Stabilised voltage 1 In motion: Clutch opened and closed at times
Buzzer, supply at output AU Stationary: Manoeuvring not possible; if starting
warning light too high (supply, off does not occur within a certain time, the
clutch sensor) gearbox shifts to neutral automatically. The new
starting gear has to be engaged using the mode
switch.
03107 STOP symbol Stabilised voltage 2 In motion: Clutch opened and closed at times
Buzzer, supply at output AU Stationary: Manoeuvring not possible; if starting
warning light too low (supply, off does not occur within a certain time, the
clutch sensor) gearbox shifts to neutral automatically. The new
starting gear has to be engaged using the mode
switch.
03111 CAN databus Time/day from ZBR, Timeout
No calculation of clutch overload
03112 CAN databus Time/day from ZBR, signal defective or missing
No calculation of clutch overload
03113 CAN databus Retarder configuration, Timeout
In motion: No calculation of driving resistance, no
automatic calculation of starting gear. Medium
starting gear is engaged when vehicle comes to a
standstill.
03114 STOP symbol Clutch actuation 0 In motion: Gear shift blocked
Buzzer, implausible At standstill: Automatic shift to neutral, gear shifts
warning light Unintentional closing blocked, continued driving not possible
of the clutch
03116 Clutch overload 0 Deterioration in clutch engagement quality when
when starting off starting off

T 74 8.11 - 7
DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03117 STOP symbol Error, programming, 0 In motion: Gear shift blocked
Buzzer, clutch At standstill: Automatic shift to neutral, gear shifts
warning light Clutch self- blocked, continued driving not possible
adjustment error Note: Error sometimes set although GV
Error sometimes programming error present
incorrectly detected Remedy: Load software 2.2d. If the error still
occurs, renew clutch actuators with production
number below 18000.
03118 STOP symbol Clutch does not 0 In motion: An attempt is made to engage gear; if
Buzzer, separate, clutch does gear is engaged, clutch remains closed. Further
warning light not open gear shifts blocked.
At standstill: If clutch does not open, engine stalls,
neutral selected automatically
Note: Mechanical problem, air supply
03119 STOP symbol Clutch does not 0 In motion: Gear shift blocked
Buzzer, engage At standstill: Delayed shift to neutral, gear shifts
warning light Clutch does not blocked, continued driving not possible
close/does not Remedy: Renew clutch actuators with production
transmit torque number below 18000
03120 Buzzer, Mechanical fault on 9 Function taken over by spare valve,
warning light small clutch valve deterioration in clutch engagement quality
"open"
03121 Buzzer, Mechanical fault on 9 Function taken over by spare valve,
warning light large clutch valve deterioration in clutch engagement quality
"open"
03122 Buzzer, Mechanical fault on 9 Function taken over by spare valve,
warning light small clutch valve deterioration in clutch engagement quality
"close"
03123 Buzzer, Mechanical fault on 9 Function taken over by spare valve,
warning light large clutch valve deterioration in clutch engagement quality
"close"
03124 STOP symbol Error, clutch travel 8 In motion: Clutch opened and closed at times
Buzzer, signal Stationary: Manoeuvring not possible; if starting
warning light Error sometimes off does not occur within a certain time, the
incorrectly detected gearbox shifts to neutral automatically.
by ECU Starting-off possible at speed above approx. 1700
Remedy: Load software 2.2d. If the error still
occurs, renew clutch actuators with production
number below 18000.
03125 Pressure limiting No system restrictions
valve, pressure
exceeds threshold
value
03126 Pressure signal No system restrictions if external air supply is
defective sufficient. Programming process time-controlled.
03127 ECU temperature 3 No system restrictions
signal defective
03128 Oil temperature 3 No system restrictions
signal defective

8.11 - 8 T 74
 DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03129 STOP symbol No shift sensor 6 In motion: During shifting, the "gear engaged"
Buzzer, signal, gear signal is transmitted as a function of the time
warning light (short-circuit, control. Further gear shifts blocked. Only shifts
positive) from neutral are possible.
At standstill: Starting gears can be shifted from
neutral
03130 STOP symbol Ground short, shift 5 In motion: During shifting, the "gear engaged"
Buzzer, sensor signal, gear. signal is transmitted as a function of the time
warning light No shift sensor control. Further gear shifts blocked. Only shifts
signal from neutral are possible.
(short-circuit, At standstill: Starting gears can be shifted from
ground) neutral
03131 STOP symbol No shift sensor 1 In motion: During shifting, the "gear engaged"
Buzzer, signal, gear signal is transmitted as a function of the time
warning light (interrupt) control. Further gear shifts blocked. Only shifts
from neutral are possible.
At standstill: Starting gears can be shifted from
neutral
03132 STOP symbol Programming error, 0 In motion: Gear shift blocked
Buzzer, position sensor, gear At standstill: Automatic shift to neutral, gear shifts
warning light blocked, continued driving not possible
03133 STOP symbol No gates, selector 6 In motion: Only gears that are assigned to
Buzzer, sensor signal (short- switched valve Y6 (gear 1/3) can be selected. If
warning light circuit, positive) an error occurs during the shift, the target gate is
engaged with time control.
Stationary: Only the lowest gear in both gates can
be engaged
03134 STOP symbol No gates, selector 5 In motion: Only gears that are assigned to
Buzzer, sensor signal switched valve Y6 (gear 1/3) can be selected. If
warning light (short-circuit, an error occurs during the shift, the target gate is
ground) engaged with time control.
Stationary: Only the lowest gear in both gates can
be engaged
03135 STOP symbol No gates, selector 1 In motion: Only gears that are assigned to
Buzzer, sensor signal switched valve Y6 (gear 1/3) can be selected. If
warning light (interrupt) an error occurs during the shift, the target gate is
engaged with time control.
Stationary: Only the lowest gear in both gates can
be engaged
03136 Buzzer, Programming error, 0 In motion: Gear shift blocked
warning light position sensor, At standstill: Automatic shift to neutral, gear shifts
gate blocked, continued driving not possible
03137 STOP symbol No sensor signal, 6 In motion: GP shift blocked during driving. Only
Buzzer, range-change group gears in the switched GP range can be selected.
warning light (GP), If error occurs during GP shifting, GP engagement
(short-circuit, takes place with time control.
positive) At standstill: Starting off possible if small GP is
engaged

T 74 8.11 - 9
DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03138 STOP symbol No sensor signal, 5 In motion: GP shift blocked during driving. Only
Buzzer, range-change group gears in the switched GP range can be selected.
warning light (GP), If error occurs during GP shifting, GP engagement
(short-circuit, takes place with time control.
ground) At standstill: Starting off possible if small GP is
engaged
03139 STOP symbol No sensor signal, 1 In motion: GP shift blocked during driving. Only
Buzzer, range-change group gears in the switched GP range can be selected.
warning light (GP), If error occurs during GP shifting, GP engagement
(interrupt) takes place with time control.
At standstill: Starting off possible if small GP is
engaged
03140 Buzzer, Programming error, 0 In motion: Gear shift blocked
warning light position sensor, At standstill: Automatic shift to neutral, gear shifts
range-change group blocked, continued driving not possible
03141 STOP symbol No sensor signal, 6 In motion: GV shift blocked. Continued driving
Buzzer, splitter group (GV) only possible with the last selected GV position. If
warning light (short-circuit, desired gear cannot be engaged, the next highest
positive) gear is engaged. If error occurs during shifting,
GV is engaged with time control.
03142 STOP symbol No sensor signal, 5 In motion: GV shift blocked. Continued driving
Buzzer, splitter group (GV) only possible with the last selected GV position. If
warning light (short-circuit, desired gear cannot be engaged, the next highest
ground) gear is engaged. If error occurs during shifting,
GV is engaged with time control.
03143 STOP symbol No sensor signal, 10 In motion: GV shift blocked. Continued driving
Buzzer, splitter group (GV) only possible with the last selected GV position. If
warning light (interrupt) desired gear cannot be engaged, the next highest
gear is engaged. If error occurs during shifting,
GV is engaged with time control.
03144 Buzzer, Programming error, 0 In motion: Gear shift blocked
warning light position sensor, At standstill: Automatic shift to neutral, gear shifts
splitter group (GV) blocked, continued driving not possible
03145 Buzzer, Range-change group 9 In motion: GP change not possible
warning light (GP) does not open, In GP-low, highest gear is engaged (6th gear)
mechanical fault In GP-high, lowest gear is engaged (7th gear)
GP does not leave Stationary: If it is not possible to shift to GP-low,
the previous position system is not available
within a defined time Note: In the event of mechanical faults, always
take clutch, driveline strain into account
03146 Buzzer, Changeover error, 9 In motion: ECU re-attempts to engage the old
warning light range-change group position. If this is not possible, the gearbox is not
shift (GP), positively engaged.
mechanical fault Stationary: If GP does not shift into low or high,
GP does not change gearbox is not available
to the new position Note: In the event of mechanical faults, always
within a defined time take clutch, driveline strain into account

8.11 - 10 T 74
 DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03147 STOP symbol Range-change group 9 In motion: ECU re-attempts to engage the old
Buzzer, does not close (GP), position. If this is not possible, the gearbox is not
warning light mechanical fault. positively engaged.
GP reaches neither Stationary: If GP does not shift into low or high,
the final position nor system is not available
the new or old Note: In the event of mechanical faults, always
position within a take clutch, driveline strain into account
defined time
03148 Buzzer, Splitter group does 9 In motion: ECU attempts to engage the next
warning light not open (GV), highest gear (gear shift). If this is not possible,
mechanical fault gear shift is blocked.
GV does not leave Loss of gear possible during driving
the previous position Stationary: If GV can no longer be shifted, system
within a defined time is not available
Note: In the event of mechanical faults, always
take clutch, driveline strain into account
03149 Buzzer, Changeover error, 9 In motion: ECU attempts to engage the next
warning light splitter shift (GV), highest gear (gear shift). If this is not possible,
mechanical fault gear shift is blocked.
GV does not change Loss of gear possible during driving
to the new position Stationary: If GV can no longer shifts, system is
within a defined time not available
Note: In the event of mechanical faults, always
take clutch, driveline strain into account
Remedy: Load software 2.2d
03150 STOP symbol Splitter group does 9 In motion: Loss of gear during driving
Buzzer, not close (GV),
System not available
warning light mechanical fault Note: In the event of mechanical faults, always
GV reaches neither take clutch, driveline strain into account
the final position nor
the new or old
position within a
defined time
03151 STOP symbol Selector cylinder 9 In motion: If error occurs during the shift, the ECU
Buzzer, does not open shifts back into the previous gear. If this is not
warning light (gate), possible for the purpose of overspeed, the next
mechanical fault possible target gear is attempted.
Gate selector Stationary: If gate can no longer be shifted,
cylinder does not system is not available
leave the previous Note: In the event of mechanical faults, always
position within a take clutch, driveline strain into account
defined time
03152 STOP symbol Selector cylinder 9 In motion: If error occurs during the shift, the ECU
Buzzer, does not shift (gate) shifts back into the previous gate position. If this is
warning light Changeover fault, not possible for the purpose of overspeed, the
gate selection, next possible target gear is attempted.
mechanical fault Loss of gear possible during driving
Gate selection Stationary: If gate can no longer be shifted,
cylinder does not system is not available
change to the new Note: In the event of mechanical faults, always
gate within a defined take clutch, driveline strain into account
time

T 74 8.11 - 11
DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03153 STOP symbol Selector cylinder 9 In motion: Loss of gear during driving,
Buzzer, does not close gearbox shifts to neutral
warning light (gate), If no gate can be engaged, system is not available
mechanical fault Note: In the event of mechanical faults, always
Gate selection take clutch, driveline strain into account
cylinder reaches Remedy: Load software 2.2d
neither the final
position nor the new
or old position within
a defined time
03154 STOP symbol Main gearbox gear 9 In motion: Gear frozen
Buzzer, does not open Stationary: Gear shifting is only allowed after the
warning light (gear), neutral signal has been achieved, otherwise
mechanical fault system not available
Gear cylinder does Note: In the event of mechanical faults, always
not leave the take clutch, driveline strain into account
previous position
within a defined time
03155 STOP symbol Main gearbox gear 9 In motion: Loss of gear during driving
Buzzer, does not close Gearbox shifts to neutral
warning light (gear), Stationary: If tooth-to-tooth position cannot be
mechanical fault prised open, system not available.
In motion: Shift Note: Most frequent error in conjunction with
cylinder does not Valeco clutch
leave neutral. In the event of mechanical faults, always take
Stationary: Clutch clutch, driveline strain into account
exceeds defined Remedy: Load software 2.2d
closing threshold
value during tooth-to-
tooth position and
does not engage the
gear
03156 STOP symbol Wrong gear 0 In motion: Automatic shift to neutral, clutch
Buzzer, engaged remains open if shift to neutral not possible. Mode
warning light switch must be used to trigger new shift.
Loss of gear during driving
Stationary: If the correct gear can be engaged,
system is available
03158 Buzzer, Gear shift sensor – 0 In motion: No system restrictions.
warning light signal leaves Main valve (Y10) is automatically activated with
engaged position gear valve (Y6 or Y7) and shifts back to final
during driving position. If gear was completely disengaged, a
suitable gear is engaged automatically as a
function of v.
Loss of gear possible
Note: Gear migration during driving can be seen
with MAN-Cats monitoring
03159 Buzzer, Range-change group 0 In motion: No system restrictions
warning light sensor – signal Main valve (Y10) is automatically activated with
leaves engaged GP valve (Y8 or Y9) and shifts back to final
position during position. If gear was completely disengaged, a
driving (GP) suitable gear is engaged automatically as a
function of v.
Loss of gear possible
Note: GP migration during driving with can be
seen with MAN-Cats monitoring
Remedy: Load software 2.2d

8.11 - 12 T 74
 DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03160 Buzzer, Splitter group sensor 0 In motion: No system restrictions
warning light – signal leaves Main valve (Y10) is automatically activated with
engaged position GP valve (Y2 or Y3) and shifts back to final
during driving (GV) position. If gear was completely disengaged, a
suitable gear is engaged automatically as a
function of v.
Loss of gear possible
Note: GV migration during driving can be seen
with MAN-Cats monitoring
Remedy: Load software 2.2d
03163 Buzzer, 1.Engine does not 0 In motion: 1. Loss of gear, gear shifts blocked.
warning light react to required Starting off possible; however, reduced clutch
torque intervention comfort.
from AS-Tronic 2. Gate migration detected during next GV shift,
2. Gate selector gear loss occurs
cylinder – signal Note: Gate migration during driving can be seen
leaves engaged with MAN-Cats monitoring
position during Remedy: Load software 2.2d
driving
03164 STOP symbol Signal error, engine 3 In motion: Driver request replaced by accelerator
Buzzer, torque, from EEC pedal position message
warning light No calculation of vehicle weight and driving
resistance, no calculation of starting gear. At the
end of the shift, the injection quantity is released,
up to the value of the accelerator pedal.
03166 STOP symbol Idling signal 3 In motion: Deceleration detected permanently,
Buzzer, permanently active manual shifting possible until standstill
warning light At standstill: System not available, starting off not
possible
03169 STOP symbol Cut-off relay in ECU 9 System not available
Buzzer, not deactivated
warning light
03170 STOP symbol Cut-off relay in ECU In motion: Gear frozen, system not available
not activated
No voltage supply
from term. 30
03171 CAN databus, In motion: Driver request replaced by accelerator
EDC signal error, pedal position message
current engine No calculation of vehicle weight and driving
torque resistance, no calculation of starting gear. At the
end of the shift, the injection quantity is released,
up to the value of the accelerator pedal.
03175 Buzzer, Error, ignition lock 4 In motion: Gear frozen
warning light signal (terminal 15) Gear shifts generally blocked as soon as ignition
lock signal drops (error verification possibly
delayed)
At standstill: Without engine speed, automatic
shift to neutral and ECU deactivated
03177 CAN databus System not available
T-CAN Busoff
03179 CAN "queue 0 System not available
overrun"
Overload during
sending of
information

T 74 8.11 - 13
DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03180 CAN EEC 1 Timeout 4 System not available
03181 CAN EEC 2 Timeout 4 System not available
03182 CAN databus, EDC cruise control/road speed missing
Timeout
Signal for output speed (2) missing, if possible,
redundant signal is used
03183 CAN databus, Engine brake from FFR missing
Timeout
In motion: No calculation of driving resistance, no
automatic calculation of starting gear. Medium
starting gear is engaged when vehicle comes to a
standstill.
No information regarding engine brake torque. If
engine brake active, shift quality may deteriorate
at the beginning of the shift.
03184 CAN databus, Retarder from retarder control unit missing
Timeout
In motion: No calculation of driving resistance, no
automatic calculation of starting gear. Medium
starting gear is engaged when vehicle comes to a
standstill
03188 STOP symbol ECU error 9 In motion: Gear shift blocked
Buzzer, (interrupt) At standstill: Automatic shift to neutral, gear shifts
warning light blocked, continued driving not possible
03189 STOP symbol ECU error 9 In motion: Gear shift blocked
Buzzer, (memory monitor) At standstill: Automatic shift to neutral, gear shifts
warning light blocked, continued driving not possible
03190 STOP symbol EOL EEPROM 3 EOL EEPROM parameters
Buzzer, parameters
out of valid range
warning light out of valid range Detection with initialisation
Detection with (ignition "ON")
initialisation
(ignition "ON")
03191 STOP symbol EOL EEPROM 3 In motion: Gear shift blocked
Buzzer, parameters, At standstill: Automatic shift to neutral, gear shifts
warning light checksum error blocked, continued driving not possible
03192 STOP symbol ECU error – 9 In motion: No calculation of driving resistance, no
Buzzer, EEPROM access automatic calculation of starting gear. Medium
warning light error (EEPROM not starting gear is engaged when vehicle comes to a
readable, affects standstill.
processor only)
03193 ECU, temperature In motion: Gear shift blocked
too high At standstill: Automatic shift to neutral, gear shifts
blocked, continued driving not possible
03196 CAN databus Timeout, total mileage from ZBR missing
Message is used for predicting clutch service life
03198 CAN databus Relative wheel speed from EBS, EBC2 (WSI)
missing
Normal manual mode possible

8.11 - 14 T 74
 DIAGNOSIS

SPN Display Description FMI Reaction when vehicle in motion/at standstill

03199 CAN databus Wheel speed information from EBS, EBC2 (WSI)
missing
In motion: No calculation of driving resistance, no
automatic calculation of starting gear. Medium
starting gear is engaged when vehicle comes to a
standstill.
03209 CAN databus Timeout, error, information from ZBR
(aux_stat_zbr#1)
03210 CAN databus Timeout, error, EC monitoring device from ZBR2,
TCO1, redundant gearbox output speed missing
No calculation of the dynamic tyre radius,
therefore poorer shift quality in automatic mode. If
output speed 1 is available, no further restrictions.
03211 CAN databus Timeout, error, gearbox check from FFR, TC1_FT
After ignition "ON": Error detected during
initialisation. System not available, gear = neutral
In motion: Gear "frozen" (shift lock)
03212 CAN databus Gearbox check from FFR (requested gear),
request_gear
After ignition "ON": Error detected during
initialisation. System not available, gear = neutral
In motion: Gear "frozen" (shift lock)
03213 CAN databus Gearbox check from FFR (requested group),
request_range, FFR sends no signal from DNR
In motion: Manual driving possible
At standstill: Manoeuvring not possible
03214 CAN databus Gearbox check from FFR (request power take-off)
PTO operation not possible
03215 EMERGENCY OFF After "emergency off on again", no system
button actuated restrictions

Definition of fault types (FMI)

Fault type (FMI) Description

1 Too high
2 Too low
3 Implausible
4 No signal available
5 Short-circuit to ground
6 Short-circuit to UBat (positive)
7 General short-circuit
8 Defective signal
9 Device fault
10 Interrupt

T 74 8.11 - 15
8.11 - 16 T 74
 DIAGNOSIS

System structure, K-lines

− TG-A

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

A143 Electronically controlled air suspension A451 Door module, driver side
A144 Control, retarder/Intarder A452 Door module, co-driver side
A302 Central computer 2 A474 Air-conditioning system
A312 Customer-specified module A483 Auxiliary air heater
A330 Gearbox control, Tipmatic AS-Tronic A486 Control unit, airbag
A402 Electronic brake system A487 Electrically adjustable driver's seat
A403 Vehicle management computer A488 Electrically adjustable co-driver's seat
A407 Instrumentation A494 Auxiliary water heater
A409 Electronically controlled air management X200 Diagnosis socket
A435 Electronic diesel control

T 74 8.15 - 1
DIAGNOSIS

− R02/R03

All the control units testable using the MAN-cats diagnosis system are connected with diagnosis socket
X200 pin ... via a K-line. The diagnosis system stimulates a certain control unit via the K-line. The control
unit replies and digitally transfers the faults stored in the fault memory via the K-line.
This also applies to the multiplex central computer ZBRO (A360) which is also connected to diagnosis
socket X3090 pin S via a K-line.

A143 Electronically controlled air suspension A409 Electronically controlled air management
A144 Control, retarder/Intarder A435 Electronic diesel control
A302 Central computer 2 A451 Door module, driver side
A330 Gearbox control, Tipmatic AS-Tronic A452 Door module, co-driver side
A402 Electronic brake system X200 Diagnosis socket
A403 Vehicle management computer X3090 Diagnosis socket, multiplex
A407 Instrumentation

8.15 - 2 T 74