N04 - 2 - MAN TeleMatics - Retrofit - TGX - 81991854502 - ENG

Electrical system
MAN TeleMatics® retrot

TGS/TGX
TGA/TGM/TGL
Editorial deadline 09/2012
Retrot instructions
81.99185-4502 2nd edition N04
MAN Truck & Bus AG Retrot instructions N04, 2nd edition
Dachauer Str. 667 Electrical system
80995 MUNICH, GERMANY MAN TeleMatics® retrot
or TGS/TGX
Postfach 50 06 20 TGA/TGM/TGL
80995 MUNICH, GERMANY - Englisch -
Printed in Germany
Retrot instructions N04
2nd edition
Electrical system
MAN TeleMatics® retrot
TGS/TGX
TGA/TGM/TGL
81.99185-4502
1
PREFACE/PUBLICATION DATA
PREFACE
These instructions are intended as a guide to help perform repair work on vehicles and units correctly.
This publication assumes that persons who use it possess the requisite technical knowledge in handling
vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do not always
correspond to the unit in question, but this does not necessarily mean they are incorrect. In such cases, plan
and carry out the repair work in accordance with the sense of the instructions.
Repair work on complex add-on units should be entrusted to our customer service or to the customer service
of the manufacturing company. These units are mentioned specically in the text.
The repair work is broken down into chapters and sub-chapters. Each sub-chapter begins with an initial page
containing a summary of the essential requirements for the specied repair work. A detailed description of
the work involved may follow the initial page.
Important instructions concerning technical safety and the safety of personnel are specically highlighted, as
indicated below.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed in order to avoid exposing
people to risk.
WARNING
Type and source of danger
• Refers to working and operating procedures which must be followed in order to avoid material
damage or destruction.
Note
An explanatory note which is useful for understanding the working or operating procedure to be
performed.
Comply with general safety regulations when performing any repair work.
We reserve the right to make modications in the course of further development.
Yours faithfully,
MAN Truck & Bus AG
Munich plant
PUBLICATION DATA
© 2012 MAN Truck & Bus AG
Not to be reprinted, duplicated by any means whatsoever or translated – in whole or in part – without the
prior written approval of MAN Truck & Bus AG. All rights under the copyright law are strictly reserved by MAN
Truck & Bus AG. If any changes are made without the written approval of MAN Truck & Bus AG then MAN
Truck & Bus AG shall not be liable for any warranty or guarantee claims arising from damage and defects
attributable to the unauthorised modication. Furthermore, MAN Truck & Bus AG shall not be liable for any
damage resulting from the unapproved modication.
Editorial Department: SAWDT, 2W Technische Informations GmbH & Co. KG, 09/2012
Typesetting: SAWDT, 2W Technische Informations GmbH & Co. KG
Printing: MAN-Werksdruckerei (on-site printing works)
2 N04 2nd edition

TABLE OF CONTENTS
Content Chapter/Page
Index 5
Introduction
Safety instructions ........................................................................................................ 7

MAN TeleMatics® ........................................................................................................ 14
Preface ................................................................................................................ 14
Retrot options ....................................................................................................... 16
List of diagnostic memory entries ................................................................................. 17
Antenna item table .................................................................................................. 17
Initial start-up
Initial start-up ............................................................................................................. 21

Installation information .............................................................................................. 21
Functional test ....................................................................................................... 23
Retrot kits
TGS and TGX with adhesive antenna ............................................................................... 29

Parts required for TGS and TGX with adhesive antenna .................................................... 29
TGS and TGX with bar antenna ...................................................................................... 31
Parts required for TGS and TGX with adhesive antenna .................................................... 31
TGA, TGM and TGL with adhesive antenna ........................................................................ 33
Parts required for TGA, TGM and TGL with adhesive antenna ............................................. 33
TGA, TGM and TGL with bar antenna ............................................................................... 35
Parts required for TGA, TGM and TGL with bar antenna .................................................... 35
Retrot material .......................................................................................................... 37
View of retrot material for MAN TeleMatics® with adhesive antenna ...................................... 37
View of retrot material for MAN TeleMatics® with bar antenna ............................................. 39
Additional drawings ..................................................................................................... 41
Additional drawings for TGS and TGX as guides .............................................................. 41
Additional drawings for TGA, TGM and TGL as guides ...................................................... 45
Installation information
Installation information .................................................................................................. 51

Arranging and attaching the adhesive antenna ................................................................ 51
Arranging and attaching the bar antenna ....................................................................... 53
Replacing the bar antenna ......................................................................................... 56
Disassembling the interior panelling ............................................................................. 59
Circuit diagrams for cable harnesses ............................................................................ 63
Routing the cable harnesses ...................................................................................... 67
TBM assembly ....................................................................................................... 70
Attaching and connecting the TBM MODULE & GPRS MODEM ........................................... 72
Roof connection cable for TopLine navigation system ........................................................ 75
Installing the MAN DriverPad® .................................................................................... 77
Converting the adapter cable (only in conjunction with an MAN DriverPad®) ............................ 79
Technical Data
Technical Data 83
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INDEX
Catchword Page
N04 2nd edition 5

INTRODUCTION
INTRODUCTION
SAFETY INSTRUCTIONS
General
Only trained personnel are permitted to perform operating, maintenance or repair work on trucks and buses
/coaches.
The following sections include summaries of important regulations listed according to major topics. These
must be observed, in order to avoid accidents which could lead to injury, damage and environmental pollution.
They constitute only a short extract from the numerous accident prevention guidelines. Of course, all other
safety regulations must be followed and the necessary measures must be taken.
Additional references to danger are contained in the instructions at points where there is a potential danger.
Accidents may happen in spite of all precautionary measures having been taken. In such an eventuality,
obtain immediate medical assistance from a doctor. This is particularly important if the accident involves skin
contact with corrosive acid, fuel penetration under the skin, scalding by hot oil, antifreeze spraying into eyes,
crushing limbs, etc.
1. Regulations for preventing accidents leading to injury to personnel
During inspection, adjustment and repair work

– Secure units during their removal.
– Support the frame when working on the air or spring suspension system.
– Keep units, ladders, stairs, steps and the surrounding area free from oil and grease.
– Do not use any tools that are not in perfect condition.
– Only authorised technical personnel are entitled to perform inspection, adjustment and repair work.
Working on the brake system

– Please use a dust extraction device if dust is released during work on the brake system.
– Perform visual, functional and effectiveness checks on the brake system after carrying out any work on it
whatsoever. These safety inspection checks (SP) must be made in accordance with the relevant statutory
regulations governing special brake inspections.
– Use a suitable test system (e.g. MAN-cats®) to check the function of the ABS/ASR systems.
– Collect any brake uid that leaks out.
– Brake uid is poisonous! Do not allow it to come into contact with food or open wounds.
– Treat hydraulic uid/brake uid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.
Working on vehicles with a compressed natural gas (CNG) system

– Vehicles with a defective compressed natural gas system may not be brought into the workshop. This also
applies to vehicles whose engines cannot be switched off by automatic emptying of the supply lines.
– When working on vehicles with a compressed natural gas system, set up a gas warning device above the
vehicle roof and in the engine compartment above the pressure governor. Further gas warning devices
must be carried by the persons working on the vehicle.
– Smoking is not allowed in areas where work on vehicles with compressed natural gas systems is carried
out. All sources of ignition must be removed from these areas.
– Before carrying out welding, the gas tanks must be removed and the gas-carrying lines must be ushed
with inert gas.
– Gas tanks must not be subject to temperatures in excess of 60°C in painting and drying booths. If
temperatures exceed this value, the gas tanks must be removed or degassed and ushed with inert gas
(e.g. nitrogen). Furthermore, gas-carrying lines must be ushed with inert gas.
Working on the compressed natural gas (CNG) system

– Work on the compressed natural gas system may only be carried out by persons who have been specically
trained to do so.
– The working area for the compressed natural gas system must be equipped with an adequate ventilation
system. The ventilation system must replace the air in the room with new air at least three times per hour.
– After following the prescribed procedures to replace standard-t components of the compressed natural
gas system, check the assembly points for leaks. Perform these checks using a leak indicator spray or a
gas warning device.
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INTRODUCTION
Operating the engine

– Only authorised personnel are permitted to start and operate an engine.
– Do not get too close to the moving parts of a running engine and do not wear baggy clothing. Use an
extractor system in enclosed spaces.
– Risk of burning when working on engines at operating temperature.
– Danger of scalding when opening the hot cooling circuit.
Suspended loads
– Persons may not stand or walk underneath suspended loads.
– Only use suitable hoists that are in top condition technically. Please also make sure that the load suspension
devices used have sufcient load capacity.
Bodies and special bodies

– Comply with the safety instructions and regulations issued by the body manufacturer in question if bodies
or special bodies are tted.
Working on high-pressure lines

– Do not attempt to tighten, loosen or open pipes and hoses (e.g. in the lubrication circuit, coolant circuit and
hydraulic oil circuit) whilst they are pressurised:
Risk of injury from liquids escaping under pressure.
Testing injection nozzles

– Please wear the relevant protective equipment.
– Keep all body parts away from the jet of fuel when checking the injection nozzles.
– Do not breathe in fuel vapour, ensure sufcient ventilation.
Work on the vehicle electrical system

– Do not disconnect the batteries whilst the engine is running!
– Always disconnect the batteries when working on vehicle electronics, central electrical system, alternators
and starters. Disconnect the negative terminal rst when disconnecting the battery. Connect the positive
terminal rst when connecting.
– Use only matching test lines or test adapters to measure at plug connectors.
– If you expect temperatures in excess of 80°C (e.g. in the dryer after painting), set the main battery switch
to "OFF" and then remove the control units.
– The frame is not intended for use as a ground return. If attachments are to be tted to the vehicle (e.g. a
wheelchair lift), additional ground cables with an adequate cross-section must be routed as well. Otherwise
the ground connection may be created along wire cables, cable harnesses, gearbox shafts, gears, etc.
Severe damage could result.
Important: battery gases are explosive!

– Oxyhydrogen gas may form in enclosed battery boxes. Take particular care after long journeys and after
charging the batteries with a battery charger.
– When the batteries are disconnected, the gas may be ignited by sparks produced by continuously operating
consumers, tachographs, etc. that cannot be switched off. Blow compressed air through the battery box
before disconnecting the batteries.
– Only tow-start a vehicle if the batteries are connected. Tow-start vehicles only if the check lamps light up
brightly, but there is insufcient battery power to start the vehicle.
Do not use a boost-charger to jump-start the vehicle!
– Always disconnect the positive cable and ground cable before boost-charging and charging batteries!
– Do not boost-charge lead gel and maintenance-free batteries. (not for "maintenance-free according to DIN")
Maximum loading capacity is 10% of the stated capacity of each battery. Parallel connections increase
capacity according to the number of batteries connected in parallel.
– Risk of short-circuit if batteries have been incorrectly connected.
– Do not place any metal objects (keys, pliers, etc.) on the batteries otherwise there may be a short-circuit
at the terminals. Risk of short-circuit.
– Disconnect the batteries and recharge them every 4 weeks if the vehicle is not in use over a prolonged
period of time.
Caution! Battery acid is poisonous and corrosive!

– Wear suitable protective clothing (gloves) when handling batteries.
Do not tip or tilt batteries as acid may emerge. Do not tip or tilt gel batteries either.
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INTRODUCTION
– Only measure voltage with suitable measuring devices! The input resistance of a measuring device should
be at least 10 MΩ.
– Connect/disconnect the plug connectors of electrical control units only when the ignition is switched off.
Electric welding
– Connect the “ANTIZAP SERVICE SENTRY” protection device (MAN item number 80.78010.0002) as
described in the instructions accompanying the device.
– If this device is not available, disconnect the batteries and rmly connect the positive cable to the ground
cable in order to make a conductive connection.
– Move the manually operated main battery switch to the driving mode position. If an electronic main battery
switch has been tted, bypass the “negative” at the power relay contacts (jumper cable > 1 mm2) and
bypass the “positive” at the power relay load contacts. Also switch on numerous power consumers, such
as: starter switch (ignition) in driving mode position, hazard warning system switch “on”, lighting switch in
position “low-beam headlights on”, fan ventilation to “maximum”. The more consumers are switched on,
the higher the protection.
When welding is complete, rst switch off all consumers and remove all jumpered connections (reset to
original condition) before connecting the batteries.
– Always ground the welding equipment as close as possible to the welding area. Do not route the welding
equipment cable parallel to the electrical cables in the vehicle.
Work on plastic tubes – risk of damage and re

– Plastic tubes must not be subject to mechanical or thermal load.
Painting work
– During painting work, electronic components may only be exposed to high temperatures (max. 95°C) for
short periods; a period of up to approx. 2 hours is permissible at max. 85°C; disconnect the batteries.
Do not paint the bolt connections of the high-pressure section of the injection system. Danger of ingress of
dirt when repair work is carried out.
Working with a tilted cab

– Keep the tilting area in front of the cab clear.
– Stay out of the area between the cab and the chassis while the cab is being tilted! Danger zone!
– Always tilt the cab over the tipping point or secure the cab with a prop.
Work on the air-conditioning system

– Refrigerant uids and vapours represent a health hazard, avoid contact and protect eyes and hands.
– Do not drain gaseous refrigerants in enclosed areas.
– Never mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant.
– Dispose of refrigerant according to instructions.
Work on the airbag or belt pretensioner units

– Work on airbags or belt pretensioner units must only be performed by personnel that can provide proof of
a specialist course at the MAN Service Academy.
– Mechanical loads, impacts, heating to over 140°C, electrical pulses and electrostatic discharge may trigger
unwanted ignition of the airbag or belt pretensioner units.
– Hot gases are released explosively when the airbag or belt pretensioner units are triggered. Airbag or belt
pretensioner units that are not tted may be catapulted around uncontrollably. For this reason, there is a
risk of injury for persons in or near the cab.
– Risk of burning when touching the hot surfaces after the airbag has been triggered.
– Do not open a triggered airbag or air cushion.
– Do not touch a triggered airbag with a destroyed air cushion with your bare hands. Wear protective gloves
made of nitrile rubber.
– Before performing any work and inspections on the airbag or belt pretensioner units, or working on the
vehicle where impacts are likely, it is necessary to switch off the ignition, remove the key from the ignition
lock, disconnect the ground cable from the battery and disconnect the plug connector for the airbag and
belt pretensioner power supply.
– Fit the driver airbag restraint system, MAN item number 81.66900-6035, to the airbag steering wheel as
instructed in the Operator's Manual.
– Only perform inspections on airbag and belt pretensioner units with devices specically intended for this
purpose. Do not use inspection lamps, voltmeters or resistance meters.
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INTRODUCTION
– After having nished all work and inspections, switch off the ignition rst, then connect the plug connector(s)
for the airbag and belt pretensioner and, as a last step, connect the battery. Please ensure there is no one
in the cab when doing this.
– Only place airbag units individually, with the impact cushion facing up.
– Do not apply grease or cleaning agents to airbags and belt pretensioners.
– Store and transport airbag and belt pretensioner units in their original packaging only. It is not permitted to
transport them inside the passenger compartment.
– Airbag and belt pretensioner units may only be stored in storage areas that can be locked, and up to a
maximum of 200 kg.
Working on the independent heating

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

Avoid extended, excessive or repeated skin contact with service products, process materials, diluting agents
and solvents. Protect your skin using a suitable skin protection agent or protective gloves. Do not use any
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INTRODUCTION
service products, process materials, diluting agents or solvents to clean your skin. Apply a moisturising skin
cream after cleaning your skin.
Service products and process materials

Do not use any containers intended for food or beverages to drain and store service products or process
materials. Please observe instructions issued by the relevant local authority on the disposal of service
products and process materials.
Coolant
Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the relevant local authority
when disposing of used coolant (mixture of antifreeze and water).
Cleaning the cooling circuit

Do not pour cleaning uids and rinsing water down the drain if this practice is restricted by specic local
regulations. However, the cleaning uid and rinsing water must, in all cases, be passed through an oil
separator with a sludge trap.
Cleaning the lter insert

When blowing compressed air through the lter insert, make sure the lter dust is collected by an extractor
system, or is blown into a dust collection bag. Otherwise, use a respiratory protection mask. Wear rubber
gloves or use a skin barrier hand cream when washing out the insert, because cleaning agents have
aggressive grease-dissolving characteristics.
Engine/gearbox oil, lter cartridges, inserts and box-type lters, desiccant cartridges
Filter inserts, cartridges and box-type lters (oil and fuel lters, desiccant cartridges for the air dryer) are
classied as hazardous waste materials. Please observe instructions issued by the relevant local authority
on the disposal of the parts mentioned above.
Used engine/gearbox oil

Lengthy or repeated skin contact with any type of engine/gearbox oil removes grease from the skin. This
can cause dry skin, irritation or skin inammation. In addition to these hazards, used engine oil contains
hazardous materials which can cause dangerous skin diseases. It is particularly important to wear gloves
during an oil change.
Handling AdBlue®
AdBlue® is a synthetically produced 32.5% aqueous urea solution used as an NOx reduction additive for diesel
engines with an SCR catalytic converter. AdBlue® is not a hazardous material. However, it disintegrates to
ammonium hydroxide and carbon dioxide during storage. For this reason, AdBlue® is classied in Germany
as water-polluting (WGK 1, water pollution class 1) and must not come in contact with waste water or seep
into the ground. Ensure good ventilation of the work place when working on the AdBlue® system and do
not eat, drink or smoke. Avoid skin and eye contact with AdBlue®, thoroughly wash your hands and apply
skin protection agent before taking breaks or nishing work. In the event of skin contact with AdBlue®, rinse
skin with water and a skin cleaning agent and remove any soiled clothing immediately. Please seek medical
advice in the event of skin irritation. In the event of eye contact with AdBlue®, rinse eyes with water or eye
rinsing solution for a minimum of 10 minutes while keeping them open; remove contact lenses beforehand
and seek medical advice if the complaint persists. Immediately call for medical advice if AdBlue® has been
swallowed. Store AdBlue® containers in their closed state and in uid-tight collecting chambers at storage
temperatures of no more than 25 °C. Absorb leaked or spilt AdBlue® with binding agents and dispose of this
according to the regulations.
5. Information for working on the Common Rail system
General
– Fuel jets can cut through the skin. There is a re risk due to atomisation of the fuel.
– Never undo the bolt connections on the high fuel pressure side of the Common Rail system when the engine
is running (high-pressure line from the high-pressure pump to the rail, at the rail and on the cylinder head
to the fuel injector). When the engine is running, the lines are under a constant fuel pressure in excess of
1800 bar. Wait for at least one minute before undoing bolt connections to allow the pressure to drop. If
necessary, check that the pressure has dropped in the rail with MAN-cats®.
– Do not remain in the vicinity of the engine when it is running.
– Do not touch live parts at the electrical connection of the fuel injectors when the engine is running.
– Any change to the original wiring may lead to the limit values of the heart pacemaker regulations being
exceeded, e.g. untwisted fuel injector wiring or insertion of a break box (terminal tester).
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INTRODUCTION
– Vehicle operators and persons with heart pacemakers are not at risk from systems with MAN Common Rail
engines in approved operation.
– Fuel jets can cut through the skin. There is a re risk due to atomisation of the fuel.
– Never undo bolt connections on the high fuel pressure side of the Common Rail system when the engine
is running (fuel injection line from the high pressure pump to the rail, at the rail and on the cylinder head to
the fuel injector).
– Do not remain in the vicinity of the engine when it is running.
– When the engine is running, the lines are under a constant fuel pressure in excess of 1800 bar.
– Wait for at least one minute before undoing bolt connections to allow the pressure to drop.
– If necessary, check that the pressure has dropped in the rail with MAN-cats®.
– Do not touch live parts at the electrical connection of the fuel injectors when the engine is running.
Information for people with pacemakers

– Any change in the original engine cabling may lead to the limit values of the heart pacemaker regulations
being exceeded, e.g. untwisted fuel injector cabling or insertion of a break box (terminal tester).
– There is no danger to the driver or any passengers with pacemakers, in approved operation.
– Vehicle operators with heart pacemakers are not at risk from systems with MAN Common Rail engines, in
approved operation.
– The product in original condition complies with all the currently known limit values for heart pacemakers.
Risk of damage due to ingress of dirt

– The components of the diesel fuel-injection system consist of high-precision parts that are subjected to
extreme loads. Due to the highly precise nature of this technology, all work on the fuel system requires the
highest possible degree of cleanliness.
– Even dirt particles over 0.002 mm can cause component failure.
Before starting work on the clean side

– Clean the engine and engine compartment while the fuel system is still closed off; when doing so, do not
use a powerful jet to clean the electrical components.
– Drive the vehicle into a clean area of the workshop in which no work is performed that could swirl up dust
(grinding or welding work, brake repairs, brake and power testing, etc.).
– Avoid air movements (possible swirling up of dust through starting of engines, workshop ventilation/heating,
draughts, etc.).
– The area of the fuel system that is still closed must be cleaned and dried by means of compressed air.
– Remove loose dirt particles such as paint akes and insulating material with a suitable suction device
(industrial vacuum cleaner).
– Cover areas of the engine compartment from which dirt particles could become detached, e.g. tilted cab,
engine compartment of bus engines, with new and clean foil covering sheets.
– Before starting disassembly, wash your hands and put on a clean working overall.
After opening the clean side

– It is not permitted to use compressed air for cleaning.
– Loose dirt must be removed during assembly work using a suitable suction device (industrial vacuum
cleaner).
– Only lint-free cleaning cloths are allowed to be used on the fuel system.
– Clean tools and working equipment before starting work.
– Only tools that are not damaged (e.g. cracked chromium plating) must be used.
– Materials such as cloths, cardboard or wood must not be used when removing and tting components, as
particles and bres may become detached from such materials.
– If paint akes should be produced when undoing connections (e.g. due to painting over the connections),
these must be carefully removed before the bolt connection is nally undone.
– The connection openings of all removed parts of the clean-side fuel system must be closed off immediately
with suitable caps.
– These sealing parts must remain packaged dust-tight until use and must be disposed of after being used
once.
– The components must then be stored carefully in a clean, closed container.
– Cleaning or test uids that have already been used must not be used for these components.
– New parts must only be taken out of the original packaging immediately before use.
– Work on removed components must be performed only at a work place equipped for this purpose.
– If removed parts are shipped, always use the original packaging of the new part.
When performing the work on bus/coach engines, it is essential that the following measures are also
observed:
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INTRODUCTION
Risk of damage due to ingress of dirt

– Before opening the clean-side fuel system:
Clean the engine areas around the pressure sockets, fuel-injection lines, rail and cylinder head cover with
compressed air.
– Remove the cylinder head cover and then clean the engine areas around the pressure sockets, fuel-injection
lines and rail once again.
– First only loosen the pressure pipe sockets:
Loosen the pressure pipe socket union nuts and unscrew four turns.
Lift the pressure pipe sockets with a special tool.
Reason: only fully remove the pressure pipe sockets when the fuel injectors have already been dismantled
so that no dirt can fall into the fuel injectors from above.
– Remove the fuel injectors.
– After removal, rinse out the injectors with a cleaning uid, making sure that the high-pressure connection
hole is facing downwards.
– Remove the pressure pipe sockets; to do this, unscrew the pressure pipe socket union nut.
– Clean the injector bore in the cylinder head.
6. Limp-home program for units with electronic control units
General information
The units have an electronic control system that monitors itself (self-diagnostics) and the unit.
As soon as there is a malfunction, the malfunction is evaluated and one of the following measures is initiated:
– Output of an SPN message with a diagnostic memory entry.

– Changeover to suitable, yet limited operation. Have malfunctions rectied by MAN Service immediately.
– The diagnostic memory entry is output directly in conjunction with MAN-cats®.
7. Assembly information
Assembling pipes
– Pipes must not be mechanically deformed during assembly work; risk of fracture.
Mounting gaskets
– Only use MAN genuine gaskets
– Make sure that the areas to be sealed are undamaged and clean.
– Do not use adhesive agents or sealing agents. If necessary, to facilitate installation, use a little grease to
stick the seal to the part to be mounted.
– Tighten the bolts evenly to the specied tightening torque value.
Mounting O-rings
– Only use MAN genuine O-rings.
– Make sure that the areas to be sealed are undamaged and clean.
Engine overhaul
– The engine's service life is inuenced by very different factors. For this reason, it is not possible to state
specic operating hours or mileage values for general overhauls.
– We are of the opinion that opening an engine or performing a general overhaul is not required, as long as
the engine has good compression values and the following operating values do not deviate considerably
from those determined at start-up.
– Charging pressure
– Exhaust gas temperature
– Coolant and lubricating oil temperatures
– Oil pressure and oil consumption
– Smoke behaviour
The following criteria have considerable inuence on the engine's service life:
– Correct performance setting according to deployment
– Correct installation
– Approval of the installation by authorised personnel
– Regular maintenance according to the maintenance schedule
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INTRODUCTION
MAN TELEMATICS®
Preface
MAN TeleMatics® is an Internet-based platform for communication and data exchange with mobile units.
In conjunction with T-Systems, MAN offers a telematics solution that combines extensive logistics functions
with the analysis of technical vehicle data. MAN TeleMatics® opens up unique possibilities for eet control,
eet management and logistics.
MAN TeleMatics® is currently available in the form of the Data Smart/Entry/Data/Dispo service packages.
MAN TeleMatics® Data Smart focuses on vehicle deployment analysis and maintenance management,
enabling forward-thinking maintenance planning and therefore drastically reducing downtime due to
workshop stopovers.
MAN TeleMatics® Entry and Data supply the data relevant for a detailed vehicle deployment analysis to
reduce consumption, wear and operating costs. The reports indicate potential for improvements at the push
of a button – they can also be used as a basis for driver training measures. Vehicle tracking + tracing functions,
maintenance management and driver management complete the range of the Entry and Data packages.
The MAN TeleMatics® Dispo services package additionally enables you to record orders, dispatch them and
transmit them to the vehicles. This optimises the ow of information, allowing you to react quicker and improve
service.
Just pressing a button displays reports that show where there is potential for improvement in the driving
approach. All the data relevant to assessing the protability of the driving approach obtained from the
deployment analysis is presented and evaluated individually. You are also given specic advice on how
the driving approach could be improved.
14 N04 2nd edition

INTRODUCTION
MAN TeleMatics® employs state-of-the-art encryption technologies to protect your data from unauthorised
access.
Your data is stored anonymously with our system partner.
MAN TeleMatics® can also be used in vehicles from other manufacturers, provided these vehicles are
equipped with an interface conforming to the FMS standard.
The FMS (Fleet Management System) interface is an industrial standard dened jointly by the commercial
vehicle manufacturers, which permits data within a certain scope, e.g. consumption, mileages, engine
speeds, running time, power take-off, etc. to be read from the CAN bus of the vehicles (see also
www.fms-standard.com).
The scope of the data that can be made available through this interface may vary depending on the vehicle
manufacturer, the vehicle type and the year of construction.
The scheduling services such as position nding, job management, etc. can always be used fully, regardless
of the vehicle type and year of construction.
The MAN DriverPad® for MAN TeleMatics® enables perfect integration of the vehicle into your logistics
processes. Trip management is at the core of this development. It can also manage more complex logistics
tasks. By automatically transferring the loading and delivery addresses for your trips and orders into the
integrated truck navigation system, you can not only ensure you are on your way to the right address but you
can also rest assured that you are taking the best route there.
Additional features such as standard messages or plain text messages simplify communication and prevent
misinterpretations. Integrated trailer management enables active assignment of truck and trailer, meaning
that the dispatcher can always identify which truck/trailer combination is currently being driven.
Perfect operation and readability – even in unfavourable conditions – is enabled by a large touch screen. For
this reason, the system is independent of manufacturers and vehicle models.
N04 2nd edition 15

INTRODUCTION
Retrot options
Material procurement via Dachau
Item number Designation

81.28104-6048* Roof connection cable for telematics navigation
81.28200-6064 MAN TeleMatics® retrot kit for TGA/TGL/TGM at roof/sheet metal roof (C/L/crew
cab), bar antenna with ADR
81.28200-6065 MAN TeleMatics® retrot kit for TGA/TGL/TGM at roof/sheet metal roof (C/L/crew
cab), bar antenna without ADR
81.28200-6066 MAN TeleMatics® retrot kit for TGA/TGL/TGM medium roof/high roof (LX, XLX, XXL
cabs), adhesive antenna with ADR (C/L/crew cab with roof-mounted air inlet)**
81.28200-6067 MAN TeleMatics® retrot kit for TGA/TGL/TGM medium roof/high roof (LX, XLX, XXL
cabs), adhesive antenna without ADR (C/L/crew cab with roof-mounted air inlet)**
81.28200-6068 MAN TeleMatics® retrot kit for TGS/TGX at roof/sheet metal roof (M/XL cab), bar
antenna with ADR
81.28200-6069 MAN TeleMatics® retrot kit for TGS/TGX at roof/sheet metal roof (M/XL cab), bar
antenna without ADR
81.28200-6070 MAN TeleMatics® retrot kit for TGS/TGX medium roof/high roof (XLX/XXL cab),
adhesive antenna with ADR (M/XL cab with roof-mounted air inlet)**
81.28200-6071 MAN TeleMatics® retrot kit for TGS/TGX medium roof/high roof (XLX/XXL cab),
adhesive antenna without ADR (M/XL cab with roof-mounted air inlet)**
81.28200-6072 MAN TeleMatics® retrot kit for TGA/TGL/TGM/TGS/TGX (all cabs) with ex works
preparation
81.28150-6007 MAN TeleMatics® NAVIGATION AND TELEMATICS DEVICE, TGA/TGL/TGM/TGS
/TGX (all cabs)
81.28140-6040 MAN TeleMatics® STAND ASSEMBLY FOR NAVIGATION AND TELEMATICS
DEVICE, TGA/TGL/TGM/TGS/TGX (all cabs)
81.28104-6052 MAN TeleMatics® MULTI-CONNECTOR CONNECTION CABLE FOR NAVIGATION
AND TELEMATICS DEVICE, TGA/TGL/TGM/TGS/TGX (all cabs)
07.98703-2002 MAN TeleMatics® USB-SCR SMART CARD READER, TGA/TGL/TGM/TGS/TGX (all
cabs)
* In conjunction with TGS and TGX retrot kits only, MAN TeleMatics® Navigation.
** Only when there is a roof-mounted air inlet in the cab
16 N04 2nd edition

INTRODUCTION
List of diagnostic memory entries

TBM – diagnostic memory entries
Fault location SPN Description Display

/MAN-cats®
Battery voltage on 00168 Supply voltage at TBM above maximum or below No
TBM minimum permissible value
Instrument failure – 01235 Only entry in TBM diagnostic memory No
CAN
CAN control unit 02000 + A DM1 message expected by the TBM from a CAN No
failure control unit control unit is missing. E.g. SPN = 02001 means
address (0 to control unit 1 is no longer on the CAN.
255)
TBM reset 03000 An unexpected TBM reset has occurred No
TBM time 03001 Time not plausible, No
Clock module faulty/not responding Yes
TBM EEPROM 03002 Permanent fault in EEPROM read/write access Yes
faulty
RAM defective 03003 Format error in TBM RAM No
TBM operating 03004 TBM ambient temperature is above 80°C Yes
temperature TBM ambient temperature is below -40°C Yes
Current at TBM 03005 Overcurrent detected by the excessive Yes
high-current temperature at the driver module
outputs too high
Position data 03010 No signal, GPS receiver (internal or external) Yes
supplied via TBM available
TBM antenna input 03011 GPS antenna current greater than 50 mA Yes
– internal GPS GPS antenna current less than 15 mA Yes
receiver
Fault in 03022 Vehicle identier not plausible Yes
determining vehicle Vehicle identier not available via CAN Yes
identier
Antenna item table

The individual parts and their item numbers can be found in the chapter titled "Retrot kits"; for adhesive
antennas: see View of retrot material for MAN TeleMatics® with adhesive antenna, 37 for bar antennas: see
View of retrot material for MAN TeleMatics® with bar antenna, 39.
N04 2nd edition 17

INTRODUCTION
The installation drawing does not depict the entire view of the side.
The full-view drawing is available under MAN item number 81.28200-8355, which can be used to aid
understanding.
Designation Item number For antenna see bill of materials

Antenna installation 81.28205-8001 Radio antenna
TGX/S Antenna installation 81.28205-8002 Radio antenna, D/E net
Antenna installation 81.28205-8003 Radio antenna, D/E net + GPS
Antenna installation 81.28200-8365 Radio antenna
TGA/L/M Antenna installation 81.28200-8367 Radio antenna, D/E net
Antenna installation 81.28200-8369 Radio antenna, D/E net + GPS
Radio-telephone antenna
81.28200-8370
installation, LHD
CB radio-telephone antenna
81.28200-8371
installation, RHD
81.28200-8372
installation, LHD
Radio-telephone antenna bundle
81.28200-8373
installation, RHD
81.28200-8374
installation, LHD
TGA/L/M/X/S Radio-telephone antenna, 2-m band
81.28200-8375
installation, RHD
Antenna installation, LHD 81.28200-8377
GSM and GPS antenna for toll system
Antenna installation, RHD 81.28200-8378
Radio-telephone antenna CB radio-telephone antenna and radio
81.28200-8004
installation, LHD antenna
Combined antenna
81.28205-8005
installation, RHD GSM + D/E net + GPS + CB
Combined antenna radio-telephone antenna
81.28205-8004
installation, LHD
18 N04 2nd edition

INITIAL START-UP
INITIAL START-UP
(1) Instrument panel (5) Glasses compartment

(2) Rocker switch (6) Air outlet
(3) MAN DriverPad® (7) Instrument panel middle section
(4) Radio
N04 2nd edition 19

INITIAL START-UP
INITIAL START-UP
Installation information
N04 2nd edition 21

INITIAL START-UP
Component(s) affected Diagnostics

• MAN TeleMatics® on-board module (TBM) with • Diagnostics via MAN-cats® are not possible.
wiring. However, the TBM can still be displayed and
• GPRS modem with SIM card. tested for operational readiness via MAN-cats®.
• Combined GPS/GPRS antenna. The list of possible diagnostic memory entries
for this system can be found in the chapter titled
Special feature "List of diagnostic memory entries". see List of
• A digital tachograph (DTCO) is required. diagnostic memory entries, 17.
Process Prior to initial start-up

• Service and hardware packages have been • Recommendation: ensure the vehicle is outside
determined. to ensure faultless GPS reception.
• Hardware has been delivered. The UDF must have been successfully installed
• Schedule customer appointment. and MAN-cats® must be used for a "trial run"
• Install the TBM and, if applicable, the MAN followed by "returning data and deleting it from
DriverPad® according to the instructions. a device memory".
• Check the basic functions using LEDs.
• Request the conversion data le (via Manted or Note
fax). • Not every panel or cover needs to be removed.
• Parametrise the vehicle using the conversion data The disassembly work required depends on the
le. works preparation and customer preference in
• MTBD informed of customer data and installed each case.
modem. It is crucial to clarify the order with the customer
• T-System carries out the activation process. and perform a vehicle analysis in advance.
Observe the following when installing the Cleanliness

hardware • Lay down paper in the cab before commencing the
• The retrot cable harnesses must be xed to the retrot.
standard cab cable harness without chang. Any rubbish, residual waste, drilling chips and
• The installation and cable routing depend on the tools must always be removed once the work is
cab equipment. complete, leaving the cab in a clean condition.
• Anything that is removed (buttons, switches,
lamps, sunblind, etc.) must undergo a functional
test once retted.
Conversion data le (UDF)

Note
The vehicle must receive new parameter
settings via a conversion data le (UDF)
when undergoing an MAN TeleMatics®
on-board module (TBM) retrot.
This UDF can be ordered via FAX or
MANTED®.
If you wish to apply for a TBM retrot via
FAX, always open a new form from the
Intranet/Extranet.
• The following information is required for the UDF:

• Number of TBM control unit tted
• Whether navigation system is tted (Yes/No) if
TopLine is installed; if there is a navigation system
please specify "Yes"
• Dangerous goods involved? (Yes/No)
• Telephone/modem selection (always modem for
promotional vehicles)
• Applications:
• MAN-cats®
• MAN-cats® 2
• Forms
• Parameter settings applications, commercial
vehicles
22 N04 2nd edition

INITIAL START-UP
Functional test
N04 2nd edition 23

INITIAL START-UP
Functional test LED behaviour
GPRS MODEM S LED

Rhythmically on/off Not registered
every 0.5 seconds
Off for 3 seconds, TBM has not yet been
ashes once congured
Off for 3 seconds, GPRS connected
ashes twice
D1 LED: On
Approx. 30 seconds Modem application
after modem reboot started normally
Communication with
head ofce is OK
D1 LED: Off
Note Still off 30 seconds after Modem application not
After completing the assembly work, reboot started
installing the UDF and, if applicable,
Was on, then goes off Communication with
once activated by the provider, the TBM
at some point head ofce is not OK
must undergo a functional test.
Switch on the ignition. The following D2 LED: On
diodes must ash or light up: Approx. 30 seconds SIM card not correctly
after reboot recognised
• (1) "S LED"
• (2) "D1 LED" Comes on again later Message to special
• (3) "D2 LED" SMSC
• (4) "DC LED" DC LED: On
• Functional test with "inactive SIM card", vehicle
has not yet been activated: Permanently lit when
"S LED": rhythmically on/off every 0.5 seconds supply voltage is
"D1 LED": ON present and ignition
"D2 LED": OFF is on
"DC LED": ON, green
• Functional test with "active SIM card", vehicle has
already been activated:
"S LED": ON, red; off for 3 seconds, ashes twice
"D1 LED": ON, green
"D2 LED": OFF
"DC LED": ON, green
24 N04 2nd edition

INITIAL START-UP
ON-BOARD MODULE
Note
After completing the assembly work,
installing the UDF and, if applicable,
once activated by the provider, the TBM
must undergo a functional test.
Switch on the ignition. The following
diodes must ash or light up:
• (1) Green LED ashing slowly (1/1 sec)

Communication system is operational.
• (2) Yellow LED permanently lit, GPS delivering
current data
LED behaviour
Green LED (TBM and communication status)

Permanently off TBM is switched off
(overrun time after ignition
"off" reached or TBM
disconnected from power
supply)
Flashing quickly (0.5 TBM is switched on.
/0.5 sec) Initialising communication
and not operational
Flashing slowly (1/1 TBM is switched on.
sec) Communication system is
operational
Yellow LED (GPS)
Permanently off GPS receiver/navigation
system off (overrun time
for GPS system after
ignition "off" has passed)
Flashing slowly (1/1 GPS receiver/navigation
sec) system on, no current
position data
Permanently on GPS receiver/navigation
system delivering current
data
N04 2nd edition 25

RETROFIT KITS
RETROFIT KITS
N04 2nd edition 27

RETROFIT KITS
TGS AND TGX WITH ADHESIVE ANTENNA

Parts required for TGS and TGX with adhesive antenna
Parts required for vehicles without preparation for MAN TeleMatics®
MAN TeleMatics® RETROFIT KIT FOR TGS/TGX MEDIUM ROOF/HIGH ROOF, ADHESIVE ANTENNA
WITHOUT ADR................................................................................................................. 81.28200-6071
WITH ADR ........................................................................................................................ 81.28200-6070
CIRCUIT DIAGRAM: TBM WITHOUT ADR............ DRAWING ............................................ 81.99192-3781
CIRCUIT DIAGRAM: TBM WITH ADR................... DRAWING ............................................ 81.99192-3780
GPRS MODEM ................................................................................................................. 81.28215-6044
BRACKET FOR MODEM ................................................................................................... 81.28215-0106
ON-BOARD TELEMATICS MODULE ................................................................................. 81.25812-7022
CABLE HARNESS ASSEMBLY FOR CAB ON-BOARD TELEMATICS MODULE.................. 81.25458-5166
TBM MODEM ADAPTER CABLE ....................................................................................... 81.28104-6049
FME-SMA ANTENNA PLUG .............................................................................................. 81.25475-0262
ADAPTER CABLE............................................................................................................. 81.28104-6039
GPS ANTENNA ASSEMBLY FOR GLUING ........................................................................ 88.28205-6140
COUNTERSUNK SCREW M3X6-CUZN ............................................................................. 06.04299-0015
Assembly accessories/small items

TBM + GPRS MODEM INSTALLATION
BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
IC SYSTEMS COVER .......................................................................................................81.A3786-0110
SELF-TAPPING SCREW ST4.2X16-C-A3 .......................................................................... 06.07220-0505
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
SELF-TAPPING SCREW ST4.2X13-C-MA.......................................................................... 06.07223-0504
CABLE HARNESS ASSEMBLY FOR TACHOGRAPH/TBM, MAN TeleMatics ® WITHOUT
ADR ................................................................................................................................. 81.25458-7013
CABLE HARNESS ASSEMBLY FOR TACHOGRAPH/TBM, MAN TeleMatics ® WITH ADR ... 81.25458-7014
Parts required for vehicles with preparation for MAN TeleMatics®

MAN TeleMatics® RETROFIT KIT FOR TGA/TGL/TGM/TGS/TGX WITH EX WORKS
PREPARATION ................................................................................................................. 81.28200-6072
GPRS MODEM ................................................................................................................. 81.28215-6044
ADAPTER CABLE............................................................................................................. 81.28104-6039

BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
SELF-TAPPING SCREW ST4.2X13 ................................................................................... 06.07223-0504
N04 2nd edition 29

RETROFIT KITS
TGS AND TGX WITH BAR ANTENNA

MAN TeleMatics® RETROFIT KIT FOR TGS/TGX FLAT ROOF/SHEET METAL ROOF, BAR ANTENNA
WITHOUT ADR................................................................................................................. 81.28200-6069
MAN TeleMatics® RETROFIT KIT FOR TGS/TGX FLAT ROOF/SHEET METAL ROOF, BAR ANTENNA WITH
ADR ................................................................................................................................. 81.28200-6068
GPRS MODEM ................................................................................................................. 81.28215-6044
GSM/GPS/CB RADIO ANTENNA ASSEMBLY .................................................................... 81.28205-6088
ADAPTER CABLE............................................................................................................. 81.28104-6039
NUT M14X0.75 ................................................................................................................. 81.28240-0154
GPS ANTENNA CABLE, 1700 MM FAKRA(C)/FAKRA(C) ................................................... 81.28104-0078
GSM ANTENNA CABLE, 1700 MM FME(F)/FAKRA(F)........................................................ 81.28104-0074
ANTENNA ANGLED CONNECTOR ................................................................................... 81.25475-0260
COUNTERSUNK SCREW M3X6 CUZN ............................................................................. 06.04299-0015
ANTENNA INSTALLATION "POSITION 3" ............. DRAWING ............................................ 81.28205-8005

BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
CABLE HARNESS FOR TACHOGRAPH, ON-BOARD TELEMATICS MODULE WITHOUT
ADR ................................................................................................................................. 81.25458-7013

PREPARATION ................................................................................................................. 81.28200-6072
GPRS MODEM ................................................................................................................. 81.28215-6044
ADAPTER CABLE............................................................................................................. 81.28104-6039
NUT M14X0.75 ................................................................................................................. 81.28240-0154

BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
N04 2nd edition 31

RETROFIT KITS
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112

32 N04 2nd edition

RETROFIT KITS
TGA, TGM AND TGL WITH ADHESIVE ANTENNA

Parts required for TGA, TGM and TGL with adhesive antenna
MAN TeleMatics® RETROFIT KIT FOR TGA/TGL/TGM MEDIUM ROOF/HIGH ROOF, ADHESIVE ANTENNA
WITHOUT ADR................................................................................................................. 81.28200-6067
MAN TeleMatics® RETROFIT KIT FOR TGA/TGL/TGM MEDIUM ROOF/HIGH ROOF, ADHESIVE ANTENNA
WITH ADR ........................................................................................................................ 81.28200-6066
GPRS MODEM ................................................................................................................. 81.28215-6044
ADAPTER CABLE............................................................................................................. 81.28104-6039

BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
ADR ................................................................................................................................. 81.25454-6323

PREPARATION ................................................................................................................. 81.28200-6072
GPRS MODEM ................................................................................................................. 81.28215-6044
ADAPTER CABLE............................................................................................................. 81.28104-6039

BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
N04 2nd edition 33

RETROFIT KITS
TGA, TGM AND TGL WITH BAR ANTENNA

Parts required for TGA, TGM and TGL with bar antenna
MAN TeleMatics® RETROFIT KIT FOR TGA/TGL/TGM FLAT ROOF/SHEET METAL ROOF, BAR ANTENNA
WITHOUT ADR................................................................................................................. 81.28200-6065
WITH ADR ........................................................................................................................ 81.28200-6064
GPRS MODEM ................................................................................................................. 81.28215-6044
ADAPTER CABLE............................................................................................................. 81.28104-6039
NUT M14X0.75 ................................................................................................................. 81.28240-0154

BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
ADR ................................................................................................................................. 81.25454-6323

PREPARATION ................................................................................................................. 81.28200-6072
GPRS MODEM ................................................................................................................. 81.28215-6044
ADAPTER CABLE............................................................................................................. 81.28104-6039
NUT M14X0.75 ................................................................................................................. 81.28240-0154

BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
N04 2nd edition 35

RETROFIT KITS
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112

36 N04 2nd edition

RETROFIT KITS
RETROFIT MATERIAL
View of retrot material for MAN TeleMatics® with adhesive antenna
(1) On-board telematics module with TBM

bracket, GPRS modem and bracket for
modem
(2) Cable harness assembly for tachograph
/TBM telematics with/without ADR
(3) GPS antenna assembly for gluing
N04 2nd edition 37

RETROFIT KITS
• Component item numbers and photos • Component item numbers and photos
Item number Item number

FME-SMA ANTENNA PLUG TBM BRACKET
81.25475-0262 81.28215-0114
IC SYSTEMS COVER
ADAPTER CABLE 81.A3786-0110 (1)
81.28104-6039 SELF-TAPPING SCREW
ST4.2X13-C-MA
06.07223-0504 (2)
GPS ANTENNA ASSEMBLY

FOR GLUING
88.28205-6140 (1)
TBM MODEM ADAPTER GPS connection (2)
CABLE GSM connection (3)
81.28104-6049
SIM CARD (1)

GPRS MODEM
81.28215-6044 (2)
BRACKET FOR
MODEM81.28215-0106
ON-BOARD TELEMATICS
MODULE
81.25812-7022
38 N04 2nd edition

RETROFIT KITS
View of retrot material for MAN TeleMatics® with bar antenna
(1) On-board telematics module with TBM

bracket, GPRS modem and bracket for
modem
(2) Cable harness assembly for tachograph
/TBM telematics with/without ADR
(3) GSM/GPS antenna assembly
N04 2nd edition 39

RETROFIT KITS
• Component item numbers and photos • Component item numbers and photos
Item number Item number

FME-SMA ANTENNA PLUG TBM BRACKET
81.25475-0262 81.28215-0114
IC SYSTEMS COVER
ADAPTER CABLE 81.A3786-0110 (1)
81.28104-6039 SELF-TAPPING SCREW
ST4.2X13-C-MA
06.07223-0504 (2)
GSM/GPS/CB RADIO
ANTENNA ASSEMBLY
81.28205-6088 (1)
TBM MODEM ADAPTER NUT M14X0.75
CABLE 81.28240-0154 (2)
81.28104-6049 GPS ANTENNA CABLE,
1700 MM FAKRA(C)
/FAKRA(C)
81.28104-0078 (3)
GSM ANTENNA CABLE,
1700 MM FME(F)/FAKRA(F)
SIM CARD (1) 81.28104-0074 (4)
GPRS MODEM ANTENNA ANGLED
81.28215-6044 (2) CONNECTOR
81.25475-0260
BRACKET FOR
MODEM81.28215-0106 GSM ANTENNA CABLE,
1700 MM FME(F)/FAKRA(F)
81.28104-0074
ON-BOARD TELEMATICS
MODULE GPS ANTENNA CABLE,
81.25812-7022 1700 MM FAKRA(C)
/FAKRA(C)
81.28104-0078
40 N04 2nd edition

RETROFIT KITS
ADDITIONAL DRAWINGS
Additional drawings for TGS and TGX as guides
Circuit diagram for MAN TeleMatics® on-board module 81.99192-3781 – sheet 1
A100 255 Central electrical system X4586 TBM plug conn.

A302 352 Central computer 2 X4745 TBM navigation unit plug conn.
A408 403 Tachograph X4983 TBM plug conn. (terminal R)
A564 748 Radio with CD Note Item in broken lines is present in other
A577 On-board telematics module equipment.
A1034 857 GPRS modem
N04 2nd edition 41

RETROFIT KITS
Note Open disconnection point on TopLine

cable harness and connect X4745/ST.
A100 255 Central electrical system Note Installation location for RHD, X1535,
A302 352 Central computer 2 X1536, X2445: "J2".
A407 342 Combined instrument
F412 163 Instrument panel fuse for tachograph
(terminal 30)
X1535 Tachograph plug conn.
X1642 Cab ground point behind instrument panel
X2445 Breakdown call plug conn.
X3119 Plug conn. for line 30009 distributor
Note Item in broken lines is present in other
equipment.
42 N04 2nd edition

RETROFIT KITS
A100 255 Central electrical system Note Item in broken lines is present in other
A302 352 Central computer 2 equipment.
A408 403 Tachograph Note Open disconnection point on TopLine
A564 748 Radio with CD cable harness and connect X4745/ST.
A577 On-board telematics module
X4586 TBM plug conn.
X4745 TBM navigation unit plug conn.
X4983 TBM plug conn. (terminal R)
N04 2nd edition 43

RETROFIT KITS
A100 255 Central electrical system

A302 352 Central computer 2
(terminal 30)
equipment.
Note Installation location for RHD, X1535,
X1536, X2445: "J2".
44 N04 2nd edition

RETROFIT KITS
Additional drawings for TGA, TGM and TGL as guides

A100 255 Central electrical system Note Item in broken lines is present in other
A302 352 Central computer 2 equipment.
A408 403 Tachograph Note Open disconnection point on telephone
A577 578 On-board telematics module cable harness and connect X2446/BU.
N04 2nd edition 45

RETROFIT KITS

(terminal 30)
equipment.
46 N04 2nd edition

RETROFIT KITS
A100 255 Central electrical system Note Open disconnection point on telephone
A302 352 Central computer 2 cable harness and connect X2446/BU.
A408 403 Tachograph
A577 578 On-board telematics module
equipment.
N04 2nd edition 47

RETROFIT KITS

(terminal 30)
equipment.
48 N04 2nd edition

INSTALLATION INFORMATION
N04 2nd edition 49

Arranging and attaching the adhesive antenna
(1) TBM bracket

(2) Adhesive antenna
(3) Cable harness
(4) MAN DriverPad®
N04 2nd edition 51

Arranging and attaching the adhesive Removing the lm

antenna
Preparatory work for the adhesive antenna
• Before afxing in position, remove the second lm

from the adhesive pad (2)
Positioning the adhesive antenna

Note
An adhesive antenna is used only on
vehicles with a medium roof or high roof
The minimum adhesion temperature is
+ 10° degrees.
• The adhesive antenna (1), an adhesive pad (3)

and a cleaning cloth (2) are included in the delivery
Attaching the adhesive pad
Note
On both left-hand drive and right-hand
drive vehicles, attach the adhesive
antenna for the GPS in the storage
compartment above the clearance lamp
on the left in the direction of travel.
The installation position must be
complied with precisely as it will otherwise
not be possible to receive a signal.
• Clean the housing of the adhesive antenna (1) on Clean the attachment position (inside
the side marked with the “h” symbol (3) beforehand of roof) with the cleaning cloth before
using the cleaning cloth afxing the adhesive antenna in place.
• Pull off the protective lm on one side of the
adhesive pad (2). Afx to the side of the adhesive • Undo the appropriate overhead storage panelling
antenna (1) housing marked with the “h” symbol and route the antenna cables to the centre of the
(3) vehicle (MAN TeleMatics® position)
• Afx the adhesive antenna (1) above the clearance
lamp (3) on the inside of the panelling (2)
• Connect the adhesive antenna: see Connecting
the adhesive antenna, 73
52 N04 2nd edition

Arranging and attaching the bar antenna
(1) Right-hand bar antenna (3) Left-hand bar antenna

(2) Centre of vehicle (4) Direction of travel
Technical data
Nut ...................................................................... M14X0.75.................................Tightening torque 7 Nm
Hole diameter for attaching the bar antenna................................................................................. 20.5 mm
Note
The size of the drill hole for the antenna foot is noted on collective drawing 81.60000-8059 sheet 2.
N04 2nd edition 53

Attaching the bar antenna on at and Removing the interior lighting
sheet metal roofs
Undoing the mounting bolts
• Remove both bulbs (1) by undoing the mounting

bolts from the bulb socket (2)
• Undo bolts (1), (2) and (3) Pulling down the ceiling cladding
Removing the lifting roof panel
Note
Position (1) shows the installation
Note position of the bar antenna.
During installation, check the lifting roof
panel for any leaks after assembly.
• The cables can be routed to the central overhead
storage and the bar antenna can be attached by
Note
carefully pulling down the lifting roof panel (2)
Pay attention to the hose when
dismantling the lifting roof panel.
• Pull down the lifting roof panel (2)

• Disconnect the cable socket housing (1) on the left
and right
• Remove the lifting roof panel (2)
54 N04 2nd edition

Drilling a new hole
Note
The hole diameter is 20.5 mm. Use the
centre of the roof glazing (dimension A)
as a reference for positioning the hole.
• Drill the hole for the bar antenna
Attaching the bar antenna
• Place the nut onto the thread of the bar antenna

(1) and tighten to Tightening torque 7 Nm
N04 2nd edition 55

Replacing the bar antenna
(1) Right-hand bar antenna

(2) Centre of vehicle
(3) Left-hand bar antenna
(4) Direction of travel
56 N04 2nd edition

Replacing the bar antenna Connecting the bar antenna
Disconnecting the plug connectors
• Insert the cables and plugs of the antenna (1)

through the hole (2) into the vehicle interior from
• If required, remove plugs (1), (2) and (3) from the the outside
socket housings
Attaching the bar antenna
Undoing the bar antenna
• Undo nut (1) Note

A second person is required to assist with
Removing the bar antenna aligning the bar antenna.
• Stabilise and align the bar antenna (1)

• Tighten the bar antenna (1) by hand with the nut
Tightening the bar antenna nut
• Carefully pull the cables and plugs of the antenna

(1) through the hole (2)
• Tighten the nut (1) to Tightening torque 7 Nm
N04 2nd edition 57

Connecting the socket housings
• Connect the GSM/GPS/CB radio antenna

assembly 81.28205-6088 (2); the GPS
antenna cable 1700 MM FAKRA(C)/FAKRA(C)
81.28104-0078 (1); and the GSM antenna cable
1700 MM FME(F)/FAKRA(F) 81.28104-0074 (3)
with the colour-coded socket housings
Routing the antenna cables
• Route the GSM antenna cable 1700 MM

FME(F)/FAKRA(F) 81.28104-0074 (2) and GPS
antenna cable 1700 MM FAKRA(C)/FAKRA(C)
81.28104-0078 (3) from the GSM/GPS/CB radio
antenna assembly 81.28205-6088 to the central
overhead storage
• Antenna cables can be secured in the overhead
storage (1) using a self-adhesive plate and cable
ties
58 N04 2nd edition

Disassembling the interior panelling

Additional work
– Disconnect and reconnect the battery; see the Operator's Manual
– Remove and ret the panelling; see repair manual U13
(1) Instrument panel

(2) Rocker switch
(3) MAN DriverPad®
(4) Radio
(5) Glasses compartment
(6) Air outlet
(7) Instrument panel middle section
N04 2nd edition 59

Disassembling the interior panelling Undoing the radio mounting
Removing the glasses compartment and

cupholder
Note
For more information, see the section on
removing and tting the radio in repair
Note manual U13-2.
For more information, see the section
on removing and tting the glasses • Remove the operating buttons
compartment in repair manual U13-2. • Undo the mounting bolts (1)
Note Removing the radio
Pay attention to the spring when
removing the glasses compartment.
• Remove the glasses compartment (1) and

cupholder (2)
Removing the instrument panel middle section
• Release the radio (1) with the hook

• Pull out the radio (1) and disconnect the electrical
connection
Note
on removing and tting the trim strips,
air outlets and instrument panel middle
section in repair manual U13-2.
• Remove the trim strips

• Remove the tray base (2)
• Remove the air outlets (1)
• Remove the instrument panel middle section (3)
60 N04 2nd edition

Removing the combined instrument Rubber door seal in A-pillar cladding
Note
on removing and tting the combined
instrument and its cover in repair manual
U13-2
• Undo the mounting bolts (4)

• Remove the rocker switch (2)
• Remove the cover for the combined instruments
(3)
• Remove the combined instrument (1)
Note
If a communication device is tted in
the A-pillar cladding, remove the mobile
phone beforehand; see the section on
removing and tting a mobile phone in
repair manual U13-2.
• Detach the rubber door seal (1) from the door

frame
• Undo the mounting bolts
• Remove the A-pillar cladding (2)
N04 2nd edition 61

Removing the pedal and steering column Removing the centre console trim
cladding

• Remove the centre console trim (1)
Note
For more information, see the section Removing the Bluetooth control unit (optional)
on removing and tting the front wall
cover on the driver's side in repair manual
U13-2.
• Remove the oor covering

• Remove the pedal cladding (1)
• Remove the steering column cladding on the
driver's side (2)
Removing the step cladding
Note
Only perform this task if a Bluetooth
control unit is installed.
• Undo plug connector (3)

• Remove the Bluetooth control unit (2) from the
bracket (1)

• Remove the step cladding (1)
62 N04 2nd edition

Circuit diagrams for cable harnesses

Circuit diagram of roof cable harness for tachograph with TBM 81.25458-7013
(1) Actuated positive (terminal 15)

(2) TBM connection
(3) Digital tachograph connections
(4) Cable harness A408/B connection
(5) Ground point connection
(6) Cable harness connection
(8) Cable harness connections
N04 2nd edition 63

Circuit diagram of roof cable harness for tachograph with TBM and ADR 81.25458-7014
(1) Actuated positive (terminal 15)

(2) TBM connection
(4) Cable harness A408/B connection
(8) Plug housing connection with cable
harness A408/A
64 N04 2nd edition

Circuit diagram of cable harness for tachograph with TBM 81.25454-6323
(1) Cable harness X1535/BU and A408/A

connection
N04 2nd edition 65

Circuit diagram of cable harness for tachograph with TBM and ADR 81.25454-6288
(1) Cable harness X1535/BU and A408/A

connection
(5) Plug housing connection with cable
harness A408/A
66 N04 2nd edition

Routing the cable harnesses
N04 2nd edition 67

Routing the cable harnesses Routing the footwell cable harness
Routing the central overhead storage cable

harness
• Route the cable harness (1) next to the combined

instrument in the footwell area and secure with
cable ties
Note
Securely attach the cable harnesses to Connecting the TGS and TGX plug connectors
be routed to the existing cables with cable
ties without them chang.
Note
ADR version:
Use cable harness assembly for
tachograph/TBM telematics with ADR.
• Route the cable harness assembly for tachograph

/TBM telematics without ADR from the central
overhead storage to the footwell via the A-pillar
• Place connector A577 (1) in the central overhead
storage
• Place connectors A408 A and A408 B in the DTCO
compartment
Routing the side panel cable harness Note

The tachograph socket housing (1)
X2445 is an addition to the cable
harness (cable harness assembly for
tachograph/TBM telematics without
ADR, or cable harness assembly for
tachograph/TBM telematics with ADR).
• Disconnect the existing plug connectors X1535 (2)

and X1536 (3)
• Connect the newly routed cable harness to socket
housings (2) and (3)
• Carefully pull up the side panel

• Route the cable harness inside and secure with
cable ties
68 N04 2nd edition

Fastening the TGS and TGX ground cable
Note
The X1642 ground point for the cab
is located behind the instrument panel,
installation location "F".
X1642 is an M6 ground pin.
• Route the cable harness assembly for the cab

on-board telematics module from X1642 ground
point (1) to plug connector X2445 at clutch pedal
height and tighten the mounting nut to 9 Nm
N04 2nd edition 69

TBM assembly
(1) GPRS modem

(2) TBM bracket
(3) On-board telematics module
(4) Self-tapping screws ST4.2x16-C-A3
(7) IC systems cover
(8) Modem bracket
70 N04 2nd edition

TBM assembly Fastening the TBM to the bracket
Removing the TBM bracket
• Fasten the on-board telematics module

81.25812-7022 (3), using nut ST4.2-2-MAN18
• Disconnect the plug (3) from the Bluetooth control 06.13189-0112 and self-tapping screws
unit ST4.2X16-C-A3 06.07220-0505 (2), to the TBM
• Remove the bracket (1) with the Bluetooth control bracket 81.28215-0114 (1)
unit (2)
Fastening the modem bracket to the TBM
Fastening the GPRS modem to the bracket bracket
• Fasten the GPRS modem 81.28215-6044 (3) to • GPRS modem 81.28215-6044 with BRACKET for
the modem bracket 81.28215-0106 (2) using 4 modem 81.28215-0106 using self-tapping screws
countersunk-head screws (1) ST4.2X16-C-A3 06.07220-0505 (2) to the TBM
bracket 81.28215-0114 (1)
N04 2nd edition 71

Attaching and connecting the TBM MODULE & GPRS MODEM
(1) Cover
(2) Cover frame
(3) Cover
(4) Cover panel for all-round curtain
(5) Side ceiling cover panel
(6) Grab handle
(7) Cowl panel, rear right
(8) Roller blind
(9) Cowl panel, front right
(10) Luminous cap
(11) Central storage
(12) IC systems cover
(13) Digital tachograph
(14) CD changer
72 N04 2nd edition

Attaching and connecting the TBM Connecting the bar antenna

MODULE & GPRS MODEM
Pin assignment for TBM module for bar antenna
• Insert the TBM modem adapter cable

81.28104-6049 (1) coming from the TBM module
into the GPRS modem and snap it into place
• (1) Unassigned • Fasten the FME-SMA antenna plug
• (2) TBM modem adapter cable 81.28104-6049 81.25475-0262 (2) and the GSM 1700 MM FME
• (3) Adapter cable 81.28104-6039 (F)/FAKRA (F) antenna cable 81.28104-0074
• (4) Antenna angled connector 81.25475-0260 and • Fasten the adapter cable 81.28104-6039 (3)
GPS 1700 MM FAKRA(C)/FAKRA(C) antenna coming from the TBM module to the GPRS
cable 81.28104-0078 modem using the existing mounting bolts
Pin assignment for TBM module for adhesive Connecting the adhesive antenna
antenna
• Insert the TBM modem adapter cable

• (1) Unassigned 81.28104-6049 (1) coming from the TBM module
• (2) TBM modem adapter cable 81.28104-6049 into the GPRS modem and snap it into place
• (3) Adapter cable 81.28104-6039 • Fasten the FME-SMA antenna plug
• (4) Antenna plug of GPS antenna assembly for 81.25475-0262 (2) and the GSM antenna
gluing 88.28205-6140 cable of the GPS antenna assembly for gluing
88.28205-6140
• Fasten the adapter cable 81.28104-6039 (3)
coming from the TBM module to the GPRS
modem
N04 2nd edition 73

Attaching the TBM module
• Fit the TBM module bracket 81.28215-0114 into

the central overhead storage
Connecting the adapter cable
• Connect plug X4586 (1) of the TBM modem

adapter cable 81.28104-6049 to plug X4586 (2)
of the cable harness once installation work is
complete in the central overhead storage
• Carry out a functional test: see Functional test, 24
74 N04 2nd edition

Roof connection cable for TopLine navigation system
(1) Plug X6
(2) Submin plug housing on TBM
(3) Cable harness
(4) Plug X4745
N04 2nd edition 75

Roof connection cable for TopLine Fastening the navigation system to the TBM
navigation system
Note
Securely attach the cable harnesses to
be routed to the existing cables with cable
ties without them chang.
Note
For vehicles equipped with a navigation
system: when ordering the conversion
data le (UDF) always state that a
navigation system has been tted.
Installation location of X4745: "H2"
for left-hand drive vehicles, "J2" for
right-hand drive vehicles.
• If the vehicle has been equipped ex works • Connect the roof connection cable for telematics
with an MAN TopLine navigation system, the navigation (81.28104-6048) to the TBM using the
roof connection cable for telematics navigation Submin plug housing
(81.28104-6048) also needs to be ordered, routed
and connected
• It is also necessary to route the roof connection
cable for telematics navigation (81.28104-6048)
from the central overhead storage (Submin plug)
to the (6-pin) plug package X4745 via the A-pillar
(on the driver's side)
Connecting the cable harness
Note
The full-view drawing is available under
MAN item number 81.99192-3781 sheet
1, see Additional drawings for TGS and
TGX as guides, 41. This can be used to
aid understanding.
Installation location of X4745: "H2"
for left-hand drive vehicles, "J2" for
right-hand drive vehicles.
• Connect the TBM navigation unit socket housing

(2) X4745 of the A577 TBM cable harness (3)
(81.28104-6048) to the A564 cable harness for
radio socket housing (1) X4745
76 N04 2nd edition

Installing the MAN DriverPad®
(1) TBM bracket (3) Cable harness

(2) Adhesive antenna (4) MAN DriverPad®
Parts required
Navigation and telematics device ....................................................................................... 81.28150-6007
Stand assembly for navigation and telematics device .......................................................... 81.28140-6040
Multi-connector connection cable for navigation and telematics device ................................. 81.28104-6052
TMC antenna cable ........................................................................................................... 81.28104-0106
N04 2nd edition 77

Installing the MAN DriverPad®

Attaching the stand
• Identify and mark the installation position

• Drill the holes in accordance with the bolt size
• Clean the surface
• Pull off the protective lm from the bottom of the
stand (1)
• Position the stand (1) on the surface and secure
using the bolts (2)
Attaching the MAN DriverPad®
• Attach the MAN DriverPad® (1) to the stand (2)
78 N04 2nd edition

Converting the adapter cable (only in conjunction with an MAN DriverPad®)
Parts required
TBM modem adapter cable (technical drawing) ................................................................... 81.28104-6049
Twin blade receptacle AFK 2.8 plus .................................................................................... 07.91201-0226
Note
Stripping length: 5 mm + /- 0.2 mm
Note
The cable numbering is printed on the cables. The slots for the cables are numbered. The numbers
are located next to each slot.
Note
In the case of the MAN CSV 10 VARIO system, the head for manual crimping pliers can be replaced.
The head for manual crimping pliers can only be used in conjunction with the basic tool (handle)
81.99625-0083. If individual heads for manual crimping pliers are reordered, the basic tool (handle)
80.99625-0083 also needs to be ordered once.
N04 2nd edition 79

Special tools
[1] Cable cutters 08.02950-0200
• Preparing for crimping
[2] Duo-Stripper stripping tool 80.99625-0041
• Stripping the cables
[3] Basic tool (handle) 80.99625-0083
• Crimping the cables in conjunction with:

• CSV 10 AFK_AFS 2.8 plus head for manual
crimping pliers [4]
[4] CSV 10 AFK_AFS 2.8 plus head for manual 80.99625-0109

crimping pliers
• Crimping the cables
[5] Unlocking tool 2.8-6.3 (Stahlwille) 80.99606-0421
• Unlocking the pins
80 N04 2nd edition

Converting the adapter cable Connecting the cable
Disconnecting the cable
• Insert cable (1) and cable (2) into the relevant slots
on plug (3)
• Release cables 4 and 6 (1) on the TBM connection • Check that the cable is securely fastened
side using Unlocking tool 2.8-6.3 (Stahlwille) [5]
• Remove the cable (1) from the plug
Assembling the cable
Note
The stripping length for crimping is 5 mm
+ /- 0.2 mm
• Remove the crimping from cables 4 and 6

• Strip cables 4 and 6 if required
• Strip the ground cable and positive cable (MAN
DriverPad® power supply)
• Crimp together the ground cable and cable 6 using
Basic tool (handle) [3] and CSV 10 AFK_AFS 2.8
plus head for manual crimping pliers [4] (1)
• Crimp together the positive cable and cable
4 using Basic tool (handle) [3] and CSV 10
AFK_AFS 2.8 plus head for manual crimping
pliers [4] (1)
N04 2nd edition 81

TECHNICAL DATA
TECHNICAL DATA

WITHOUT ADR................................................................................................................. 81.28200-6071
WITH ADR ........................................................................................................................ 81.28200-6070
GPRS MODEM ................................................................................................................. 81.28215-6044
ADAPTER CABLE............................................................................................................. 81.28104-6039

BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
ADR ................................................................................................................................. 81.25458-7013

PREPARATION ................................................................................................................. 81.28200-6072
GPRS MODEM ................................................................................................................. 81.28215-6044
ADAPTER CABLE............................................................................................................. 81.28104-6039

BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112

WITHOUT ADR................................................................................................................. 81.28200-6069
WITH ADR ........................................................................................................................ 81.28200-6068
GPRS MODEM ................................................................................................................. 81.28215-6044
N04 2nd edition 83

TECHNICAL DATA

ADAPTER CABLE............................................................................................................. 81.28104-6039
NUT M14X0.75 ................................................................................................................. 81.28240-0154

BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
CABLE HARNESS FOR TACHOGRAPH, ON-BOARD TELEMATICS MODULE WITHOUT
ADR ................................................................................................................................. 81.25458-7013

PREPARATION ................................................................................................................. 81.28200-6072
GPRS MODEM ................................................................................................................. 81.28215-6044
ADAPTER CABLE............................................................................................................. 81.28104-6039
NUT M14X0.75 ................................................................................................................. 81.28240-0154

BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
MAN TeleMatics® RETROFIT KIT FOR TGA/TGL/TGM MEDIUM ROOF/HIGH ROOF, ADHESIVE
ANTENNA WITHOUT ADR ................................................................................................ 81.28200-6067
MAN TeleMatics® RETROFIT KIT FOR TGA/TGL/TGM MEDIUM ROOF/HIGH ROOF, ADHESIVE
ANTENNA WITH ADR ....................................................................................................... 81.28200-6066
GPRS MODEM ................................................................................................................. 81.28215-6044
84 N04 2nd edition

TECHNICAL DATA

ADAPTER CABLE............................................................................................................. 81.28104-6039
BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
ADR ................................................................................................................................. 81.25454-6323
PREPARATION ................................................................................................................. 81.28200-6072
GPRS MODEM ................................................................................................................. 81.28215-6044
ADAPTER CABLE............................................................................................................. 81.28104-6039
BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
WITHOUT ADR................................................................................................................. 81.28200-6065
WITH ADR ........................................................................................................................ 81.28200-6064
GPRS MODEM ................................................................................................................. 81.28215-6044
ADAPTER CABLE............................................................................................................. 81.28104-6039
NUT M14X0.75 ................................................................................................................. 81.28240-0154
N04 2nd edition 85

TECHNICAL DATA
BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
ADR ................................................................................................................................. 81.25454-6323
PREPARATION ................................................................................................................. 81.28200-6072
GPRS MODEM ................................................................................................................. 81.28215-6044
ADAPTER CABLE............................................................................................................. 81.28104-6039
NUT M14X0.75 ................................................................................................................. 81.28240-0154
BRACKET............................................................ DRAWING ............................................ 81.28240-8002
TBM BRACKET................................................................................................................. 81.28215-0114
NUT ST4.2-2-MAN18 ........................................................................................................ 06.13189-0112
Arranging and attaching the bar antenna

Nut ...................................................................... M14X0.75.................................Tightening torque 7 Nm
Hole diameter for attaching the bar antenna................................................................................. 20.5 mm
86 N04 2nd edition

N04 - 2 - MAN TeleMatics - Retrofit - TGX - 81991854502 - ENG

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Electrical system

MAN TeleMatics® retrot

Editorial deadline 09/2012

We reserve the right to make modications in the course of further development.

MAN Truck & Bus AG

© 2012 MAN Truck & Bus AG

Typesetting: SAWDT, 2W Technische Informations GmbH & Co. KG

Printing: MAN-Werksdruckerei (on-site printing works)

2 N04 2nd edition

Safety instructions ........................................................................................................ 7

Initial start-up ............................................................................................................. 21

TGS and TGX with adhesive antenna ............................................................................... 29

Installation information .................................................................................................. 51

N04 2nd edition 3

N04 2nd edition 5

1. Regulations for preventing accidents leading to injury to personnel

During inspection, adjustment and repair work

Working on the brake system

Working on vehicles with a compressed natural gas (CNG) system

Working on the compressed natural gas (CNG) system

N04 2nd edition 7

Operating the engine

Bodies and special bodies

Working on high-pressure lines

Testing injection nozzles

Work on the vehicle electrical system

Important: battery gases are explosive!

Caution! Battery acid is poisonous and corrosive!

8 N04 2nd edition

Work on plastic tubes – risk of damage and re

Working with a tilted cab

Work on the air-conditioning system

Work on the airbag or belt pretensioner units

N04 2nd edition 9

Working on the independent heating

2. Guidelines for preventing damage and premature wear on units

3. Limited liability for spare parts and accessories

4. Regulations for avoiding injury and environmental contamination

Health protection precautions

10 N04 2nd edition

Service products and process materials

Cleaning the cooling circuit

Cleaning the lter insert

Used engine/gearbox oil

5. Information for working on the Common Rail system

N04 2nd edition 11

Information for people with pacemakers

Risk of damage due to ingress of dirt

Before starting work on the clean side

After opening the clean side

12 N04 2nd edition

Risk of damage due to ingress of dirt

6. Limp-home program for units with electronic control units

– Output of an SPN message with a diagnostic memory entry.

N04 2nd edition 13

14 N04 2nd edition

Your data is stored anonymously with our system partner.

N04 2nd edition 15

Material procurement via Dachau

Item number Designation

16 N04 2nd edition

List of diagnostic memory entries

Fault location SPN Description Display