ZDR INTERFACE WITH VEHICLE MANAGEMENT COMPUTERS FOR

EXTERNAL SPEED CONTROLS WITH THE TRUCKNOLOGY GENERATION

1.

Area of application

2.

Terms and abbreviations used

3.

Valid guidelines and standards

4.

Addresses and areas of responsibility

5.

General notes on the ZDR/FFR interface

6.

Notes on intermediate speed control (ZDR)

6.1.

Basic functions

6.2.

Programming possibilities

4
6

7.

Pin description and block diagrams

8.

List of interfaces and sites

14

9.

Typical circuits

15

Interfaces TG - ZDR/FFR

1.

Area of application

This interface description is applicable for all body structure manufacturers who require external speed control on MAN commercial
vehicles. The standard interface design described here concerns Trucknology Generation (TG) vehicles.

2.

Terms and abbreviations used

The following specialist terms and abbreviations are used in the PIN description:
Term/abbreviation

Explanation

AUS (in English: OFF)

Disengages FGR/FGB/ZDR functions

EMV

Electromagnetic compatibility (in German: elektromagnetische Vertrglichkeit)

FGR/FGB/ZDR

Speed control/speed restriction/intermediate speed control (in German: Fahrgeschwindigkeitsregelung/Fahrgeschwindigkeits-begrenzung/Zwischendrehzahlregelung)

FFR

Vehicle management computer (in German: Fahrzeugfhrungsrechner)

GETRIEBE-N (in English: GEARBOX N) Gearbox in neutral position

HP

ZF automatic gearbox HP...

HGB

Top speed restriction (in German: Hchstgeschwindigkeitsbegrenzung)

KSM

Customer-specic control module (in German: Kundenspezisches Steuermodul)

LED

Light emitting diode

MDB

Torque/speed restriction (in German: Moment-/Drehzahlbegrenzung)

M3135

MAN company standard (letter M + 4-digit number)

MAN-CATS II

Computer diagnosis system of MAN workshops

MEMORY

Resumption of a stored function

NA

Power take-off (in German: Nebenabtrieb)

PIN

Plug-in contact

R-Gang

Reverse gear (in German: Rckwrtsgang)

SET+

Accelerate or increase the number of revs and set

SET-

Slow down or decrease the number of revs and set

SG

Control unit

+UBAT

Plus voltage of the batteries

-UBAT

Minus voltage of the batteries

ZDR

Intermediate speed regulation/regulator (in German: Zwischendrehzahlregelung/-regler)

3.

Reference directives and standards

Currently valid MAN guide to tting bodies, released on the internet at www.manted.de, here in particular the booklets
Elektrik (in English: Electrics), Trucknology Generation and Schnittstellen TGA (in English: TGA interfaces) including all
supplementary information from the body manufacturers.
MAN performance specications relays for commercial vehicles
MAN standard M 3285 (EMV) as well as EU directive 72/245/EEC incl. 95/54/EEC
MAN standard M 3135 (electrical lines)
DIN 40 050
DIN 40 839 Sections 1, 3 and 4
DIN 57 879, Section 3
VDE 0879, Section 3
VG 95 370 to 95 377
MIL-STO 461 and 462

Interfaces TG - ZDR/FFR

4.

Addresses and competencies

Sources of supply are indicated in the MAN guide to tting HGV bodies. These are as available from:
MAN Nutzfahrzeuge AG / Abt. ESC (Fax: +49 089 1580 4264)
Postfach 50 06 20
D-80976 Munich, Germany
MAN guides to tting bodies are released on the internet at www.manted.de in order to ensure the latest version.

5.

General information on the ZDR interface with FFR

The interface is already included in the vehicles standard delivery specications.
The required parameters in the FFR-SG such as speeds, etc. must be notied to MAN Sales on placing the order for
programming at the factory. In particular, the type of body (e.g. crane, set-down system, cement pump...) must be indicated,
as branch-specic designs are available ex-factory for these.
The Start-Stop facility is independent of the interface for external speed control and has to be ordered separately.
The lines for an external control unit (engine start-stop) may lie rolled-up in the end of the frame, depending on the version.
The reverse lock facility for refuse vehicles is not part of the interface and must be ordered separately.
The utmost care must be taken when connecting the interface, as it involves major intervention into the electrical
system and into the wiring of the electronic system.
Only use electrical lines which conform to MAN standard M 3135.
Only use relays which are in accordance with MAN relay performance specications for external connection.
Proper crimping of contacts according to contact manufacturers instructions must be guaranteed.
External control elements of the body must comply with protection type IP69K according to DIN 40 050 and must also be
safeguarded against any inadvertent outside intervention.
The power supply (+UBAT) of any units and controls belonging to the body must be tapped from the batteries using
separate and suitable line protection. Tapping +12 Volt at just one battery is inadmissible.
As a ground supply, a separate cable must be laid to the common grounding point on the engine bearing (the vehicle frame
should not be used as a grounding conductor!).
Different ground potentials of the external wiring should not be connected with each other.
The interface wiring must be isolated from the load circuit of the control unit for the body.
The external wiring must meet the requirements of MAN M 3285 for commercial vehicle systems.
Similarly, any radio technology systems (e.g. belonging to a radio control) of the functions described in the performance
specications should not affect commercial vehicle functions.
If, in the case of vehicles with power take-off (German abbreviation NA), power take-off is requested via the ZDR interface,
power take-off can only be deactivated by removing the switch-on signal and not by actuating the power take-off switch in
the drivers cab.
Any examples of typical circuits issued by MAN for illustration purposes must never be taken as construction
instructions. Anyone doing the interface wiring must also accept liability in this respect.

Interfaces TG - ZDR/FFR

6.

Information on the intermediate speed regulator

6.1.

Basic functions

The intermediate speed regulator (German abbreviation ZDR) is used to set a constantly regulated engine speed.
Up to 8 different intermediate speeds can be set directly using MAN-cats II.

ZDR 1, ZDR 2, . . . . , ZDR 7:

These intermediate speeds are engaged by activating corresponding ZDR pins e.g. on engaging power take-off.

ZDR S:
This intermediate speed is engaged by pressing the MEMORY button when none of the ZDR pins are activated.
Other intermediate speeds are possible up to the top speed limit in the respective ZDR by engaging with SET+
or by activating a restriction.
All intermediate speeds can if they are activated be manually corrected up or down within a framework determined by
MAN-cats II using the control unit. If the corresponding function is released using MAN-cats II, the corrected speeds may be
stored. If not, the value that was programmed originally is engaged again when the ZDR is engaged again.

6.2.

Programming possibilities
Within the ZDR S, 1, 2, . . . . , ZDR 7, the following functions can be programmed using MAN-cats II:

Intermediate speed:
On activating the corresponding ZDR pins (X1996/Pin 2, 7 and 8), automatically engaged set-point speed.

Lower speed limit (with ZDR S, 1, 2, . . . . , ZDR 7) is set:

reached by actuating the SET button

Upper speed limit (with ZDR S, ZDR 1, ZDR 2, . . . . , ZDR 7) is set:

reached by actuating the accelerator pedal

reached by actuating the SET+ button

Control element functions
Disengage preconditions
Control parameter set
Pedal movement sensor
Maximum torque
Automatic resumption

If engage preconditions are fullled and the mode is requested, the mode with the speed programmed using the memory is taken up.
If a precondition is no longer met, the mode goes to the lower speed limit. If engage preconditions are fullled again, the mode with
the speed programmed using MEMORY is engaged again automatically.
Note:
This function is only active in ZDR modes 1 to 7. In ZDR mode S, the function is inactive.

Automatic resumption - cement pump

This function can also be requested when the engine is switched off.
After the engine has started, the mode with the lower speed limit is engaged.
Note:
This function is only active in ZDR modes 1 to 7. In ZDR mode S, the function is inactive.

The control unit functions are SET+, SET-, MEMORY and AUS

SET+ and SET- allow the intermediate speed to be continually increased or reduced during actuation or gradually
increased or reduced by the respectively programmed increment (standard 10rpm) by entering (t 200ms).

With MEMORY

with ZDR S, ZDR 1, ZDR 2, . . . . , ZDR 7 engaged after manual change, the original set-point value of
the ZDR that has just been engaged is engaged again.

with ZDR S, ZDR 1, ZDR 2, . . . . , ZDR 7 not engaged, ZDR S is engaged, i.e. the programmed set-point
value ZDR S is engaged.

Interfaces TG - ZDR/FFR

With AUS
on vehicles produced up to 04/2001

with ZDR S, ZDR 1, ZDR 2, . . . . , ZDR 7 engaged, ZDR is switched off and idle speed engaged.
on vehicles with anticipated production from 05/2001

with ZDR S engaged, ZDR switched off and idle speed is engaged.

with ZDR 1, 2 . . . . or ZDR 7 engaged, the lower speed limit of the ZDR that has just been engaged is engaged
using MAN-cats II. The ZDR is only switched off completely by removing the signal necessary for engaging, e.g.
by engaging power take-off. The upper speed limit continues to remain active.
Control unit functions non-active, active without saving and active with saving (settable using MAN-cats II)

With control unit function active without saving, the originally programmed intermediate speed is engaged again
after disengaging the ZDR and engaging it again.

With control unit function active with saving, an arbitrary value within the programmed lower and upper speed limit
can be selected for the set-point speed. This is saved when the ZDR is engaged, by pressing the MEMORY
button (t 2000ms). By hitting the MEMORY button or engaging the ZDR again, the saved intermediate speed is
engaged.
Disengage preconditions:
Different disengage preconditions can be parameterised for the ZDR using MAN-cats II.

Disengage preconditions can be parameterised for the different functions in each case. If there is one (or several)
function(s) with the correspondingly congured disengage precondition, this leads to the same status as activating
the AUS (in English OFF) key.
Functions with programmable disengage preconditions are:
brake (service brake/engine brake/retarder): active or non-active
Parking brake: neutral or actuated or not actuated
Exceeding speed threshold for disengaging ZDR
Gear N: neutral or gear in neutral position or gear not in neutral position
Clutch: neutral or disengaged or engaged
Ramp steepness for intermediate speed at standard value or fast power-up
If the standard value (fast power-up) for the power-up speed (intermediate speed) is too low (high), this can be increased
(reduced) by programming to fast power-up (standard value). Ramp steepness can also be parameterised to standard or
fast power-up when the ZDR is disengaged.

Ramp steepness for SET+/SET- at standard or fast power-up

If the standard value (fast power-up) for the power-up speed (SET+) is too low (high), this can be increased
(reduced) by programming to fast power-up (standard value). Ramp steepness for SET- can also be
parameterised to standard or fast power-up.
Control parameter set:
The standard or cement pumps control parameter sets can be selected for each ZDR using MAN-cats II. If the deviation
is too great in the event of load changes, this can be reduced with the cement pumps setting.
Pedal movement sensor:
MAN-cats II allows the pedal movement sensor function (with ZDR S, ZDR 1, . . . . , ZDR 7) to be programmed to active or
non-active (impossible to overstep the ZDR that has been engaged using the accelerator).
Speed thresholds for disengaging ZDR modes (with ZDR S, ZDR 1, . . . . , ZDR 7):
MAN-cats II allows speed thresholds up to 5 km/h or over 5 km/h to be selected.

Speed threshold up to 5 km/h:

is the basic setting (no preconditions)

Speed threshold over 5 km/h:

can only be selected if the following precondition is fullled:
Disengage precondition gear N is programmed to gear in neutral position. Activation of the corresponding ZDR is
then only possible when the gear is in neutral position.

Interfaces TG - ZDR/FFR

7.

Pin description and circuit diagrams

+UBat (connector X1996/pin 1)

+UBat -switching signal outlet, same potential as FFR control unit supply (Cl.15)
Load:
max. 1.5A
Function:
Information that the FFR is supplied with Cl.15 (ignition on).
Useful, for example, for releasing speed or power take-off functions.
ZDR 1+3+5+7 (connector X1996/pin 2)
+UBat -switch-on signal input for controlling intermediate speed 1, 3, 5 and 7.
Function:
If the input is connected with +UBat, the intermediate speed 1 that has been programmed using MAN-cats II is engaged and
regulated as long as +UBat is connected.
If +UBat is removed, ZDR 1 disengages and the engine returns to idling speed.
If, at the same time as ZDR 1+3+5+7, the input ZDR 2+3+6+7 (X1996/Pin 7) is also connected, the intermediate speed 3 that is
programmable using MAN-cats II is engaged and regulated for as long as +UBat is applied at both inputs (X1996/Pin 2 and 7).
If +UBat is removed from both inputs, ZDR 3 disengages and the engine returns to idling speed.
If, at the same time as ZDR 1+3+5+7, the input ZDR 4+5+6+7 (X1996/Pin 8) is also connected, the intermediate speed 5 that is
programmable using MAN-cats II is engaged and regulated for as long as +UBat is applied at both inputs (X1996/Pin 2 and 8).
If +UBat is removed from both inputs, ZDR 5 disengages and the engine returns to idling speed.
If, at the same time as ZDR 1+3+5+7, inputs ZDR 2+3+6+7 (X1996/Pin 7) and ZDR 4+5+6+7 (X1996/Pin 8) are also connected,
the intermediate speed 7 that is programmable using MAN-cats II is engaged and regulated for as long as +UBat is applied to
the three inputs (X1996/Pin 2, 7 and 8).
If +UBat is removed from all 3 inputs, ZDR 7 disengages and the engine returns to idling speed.
Function release:
As soon as +UBat is applied after the engine has started.
NA1 (plug-in connector X1996/pin 3)

Manual gearbox, automated gearbox or automatic gearbox (ZF-HP):

+UBat switch-on signal output. If the NA1 switch is not activated (contact open), the FFR pin is at low level (digital input,
4,75k pull-down, switching level Ulow<2V / Uhigh>12V) NA1 request. This pin also allows NA1 to be requested with
automated gearboxes or automatic gearboxes (ZF-HP).
Only if NA1 gearshift mechanism is installed.

Load:
max. 500mA
Function:
Information that NA1 was requested or can be used for the NA1 request.
NA1 is only connected, however, if the preconditions exist that were parameterised in the FFR
(using vehicle data le or MAN-cats II), namely:

NA1 connection only with gear N active/non-active

NA1 connection only with clutch engaged active/non-active
NA1 connection only with parking brake engaged active/non-active
NA1 connection only with vehicle standstill active/non-active

Interfaces TG - ZDR/FFR

Note:
-

With manual gearbox, NA1 connection is only ever possible with vehicle standstill and disengaged clutch; it is not possible
to alter these connection preconditions.
With automated gearbox, NA1 connection is only ever possible with vehicle standstill and gear N; it is not possible to alter
these connection preconditions.
With automatic gearbox (ZF-HP), NA 1 connection is only ever possible at an engine = 900 rpm.
Connection is not possible at a higher speed.

Useful for releasing speed functions or power take-off functions in order to prevent any undesirable outside intervention in control
elements outside the drivers cab.
Note:
The NA1 gearshift mechanism is not included in the vehicles standard delivery specication and has to be ordered separately.
NA1 LIMIT SWITCH (plug-in connector X1996/pin 4)

Manual gearbox, automated gearbox or automatic gearbox (ZF-HP):

-UBat switch-on signal output, same potential as at the LED in switch NA1 of the limit switch with NA1 engaged.
If NA1 is not activated (contact open), the FFR pin is at high level (ca. +UBat ) (digital input, 4,75k pull-up, switching level
Ulow<2V / Uhigh>12V), NA1 limit switch.
Only if NA1 gearshift mechanism is installed.

Load:
max. 500mA
Function:
Information that the NA1 is engaged.
Useful for releasing speed functions or power take-off functions in order to prevent any undesirable outside intervention in control
elements outside the drivers cab.
Note:
The NA1 gearshift mechanism is not included in the vehicles standard delivery specication and has to be ordered separately.
NA2 (plug-in connector X1996/pin 5)

Manual gearbox, automated gearbox or automatic gearbox (ZF-HP):

+UBat switch-on signal output. If the NA2 switch is not activated (contact open), the FFR pin is at low level (digital input,
4,75k pull-down, switching level Ulow<2V / Uhigh>12V) NA2 request. This pin also allows NA2 to be requested with
automated gearboxes or automatic gearboxes (ZF-HP).
Only if NA2 gearshift mechanism is installed.

Load:
max. 500mA
Function:
Information that NA2 was requested or can be used for the NA2 request.
NA2 is only connected, however, if the preconditions exist that were parameterised in the FFR
(using vehicle data le or MAN-cats II), namely:

Note:
-

NA2 connection only with gear N active/non-active

NA2 connection only with clutch engaged active/non-active
NA2 connection only with parking brake engaged active/non-active
NA2 connection only with vehicle standstill active/non-active

With a manual gearbox, NA1 connection is only ever possible with vehicle standstill and disengaged clutch; it is not possible
to alter these connection preconditions.
With an automated gearbox, NA1 connection is only ever possible with vehicle standstill and gear N; it is not possible to
alter these connection preconditions.
With an automatic gearbox (ZF-HP), NA 1 connection is only ever possible at an engine 900 rpm. Connection is not possible
at a higher speed.

Interfaces TG - ZDR/FFR

Useful for releasing speed functions or power take-off functions in order to prevent any undesirable outside intervention in control
elements outside the drivers cab.
Note:
The NA2 gearshift mechanism is not included in the vehicles standard delivery specication and has to be ordered separately.
NA2 LIMIT SWITCH (plug-in connector X1996/pin 6)

Manual gearbox, automated gearbox or automatic gearbox (ZF-HP):

-UBat switch-on signal output, same potential as at the LED in switch NA2 of the limit switch with NA2 engaged. If NA2 is not
activated (contact open), the FFR pin is at high level (ca. +UBat ) (digital input, 4,75k pull-up, switching level
Ulow<2V / Uhigh>12V), NA2 limit switch.
Only if NA2 gearshift mechanism is installed.

Load:
max. 500mA
Function:
Information that the NA2 is engaged.
Useful for releasing speed functions or power take-off functions in order to prevent any undesirable outside intervention in control
elements outside the drivers cab.
Note:
The NA2 gearshift mechanism is not included in the vehicles standard delivery specication and has to be ordered separately.
ZDR 2+3+6+7 (plug-in connector X1996/pin 7)
+UBat switch-on signal input for controlling intermediate speed 2, 3, 6 and 7.
Function:
If the input is connected with +UBat, the intermediate speed 2 that has been programmed using MAN-cats II is engaged and
regulated as long as +UBat is connected.
If +UBat is removed, ZDR 2 disengages and the engine returns to idling speed.
If, at the same time as ZDR 2+3+6+7, the input ZDR 1+3+5+7 (X1996/Pin 2) is also connected, the intermediate speed 3 that is
programmable using MAN-cats II is engaged and regulated for as long as +UBat is applied at both inputs (X1996/Pin 2 and 7).
If +UBat is removed from both inputs, ZDR 3 disengages and the engine returns to idling speed.
If, at the same time as ZDR 2+3+6+7, the input ZDR 4+5+6+7 (X1996/Pin 8) is also connected, the intermediate speed 6 that is
programmable using MAN-cats II is engaged and regulated for as long as +UBat is applied at both inputs (X1996/Pin 7 and 8).
If +UBat is removed from both inputs, ZDR 6 disengages and the engine returns to idling speed.
If, at the same time as ZDR 2+3+6+7, inputs ZDR 1+3+5+7 (X1996/Pin 2) and ZDR 4+5+6+7 (X1996/Pin 8) are also connected, the
intermediate speed 7 that is programmable using MAN-cats II is engaged and regulated for as long as +UBat is applied to the three
inputs (X1996/Pin 2, 7 and 8).
If +UBat is removed from all inputs, ZDR 7 disengages and the engine returns to idling speed.
Function release:
As soon as +UBat is applied after the engine has started.

Interfaces TG - ZDR/FFR

ZDR 4+5+6+7 (plug-in connector X1996/pin 8)

+UBat switch-on signal input for controlling intermediate speed 4, 5, 6 and 7.
Function:
If the input is connected with +UBat, the intermediate speed 4 that has been programmed using MAN-cats II is engaged and
regulated as long as +UBat is connected.
If +UBat is removed, ZDR 4 disengages and the engine returns to idling speed.
If, at the same time as ZDR 4+5+6+7, the input ZDR 1+3+5+7 (X1996/Pin 2) is also connected, the intermediate speed 5 that is
programmable using MAN-cats II is engaged and regulated for as long as +UBat is applied at both inputs (X1996/Pin 2 and 8).
If +UBat is removed from both inputs, ZDR 5 disengages and the engine returns to idling speed.
If, at the same time as ZDR 4+5+6+7, the input ZDR 2+3+6+7 (X1996/Pin 7) is also connected, the intermediate speed 6 that is
programmable using MAN-cats II is engaged and regulated for as long as +UBat is applied at both inputs (X1996/Pin 7 and 8).
If +UBat is removed from both inputs, ZDR 6 disengages and the engine returns to idling speed.
If, at the same time as ZDR 4+5+6+7, inputs ZDR 1+3+5+7 (X1996/Pin 2) and ZDR 4+5+6+7 (X1996/Pin 7) are also connected, the
intermediate speed 7 that is programmable using MAN-cats II is engaged and regulated for as long as +UBat is applied to the three
inputs (X1996/Pin 2, 7 and 8).
If +UBat is removed from all 3 inputs, ZDR 7 disengages and the engine returns to idling speed.
Function release:
As soon as +UBat is applied after the engine has started.
MDB INPUT (plug-in connector X1996/pin 9)
Resistance-coded switching signal input for connecting different torque/speed characteristics.
Function:
Through connecting the input with the standard external bridge (between X1996/Pin9 and 12), the torque/speed characteristic 0
(drive characteristic) is activated.
If the torque/speed characteristic 1 (limited drive characteristic 1) is required, this must be activated by switching
(switches, relays, etc.) from MDB switching signal output 0 (X1996/Pin 12) to MDB-switching signal output 1 (X1996/Pin 11).
If the torque/speed characteristic 2 (limited drive characteristic 2) is required, this must be activated by switching
(switches, relays, etc.) from MDB switching signal output 0 (X1996/Pin 12) to MDB-switching signal output 2 (X1996/Pin 10).
Function release:
Immediately after activation
Note:
If the input remains unused for longer than 1 second or if a false or implausible signal is applied, this leads to an error entry
in the FFR control unit.

Interfaces TG - ZDR/FFR

MDB 2 (plug-in connector X1996/pin 10)

Resistance-coded switching signal output for switching torque/speed characteristic 2 (limited drive characteristic 2; standard: speed
restriction of the drive characteristic).
Function:
If the MDB switching signal input (X1996/Pin 9) is connected with this signal, torque/speed characteristic 2 (limited drive
characteristic 2) is activated. By activating the restricted drive characteristic 2, the drive characteristic is limited to speed restriction 2
which is programmable using MAN-cats II.
Factory setting:
1350 rpm at 100% torque
MDB 1 (plug-in connector X1996/pin 11)
Resistance-coded switching signal output for connecting torque/speed characteristic 1 (restricted drive characteristic 1; standard:
speed restriction of the drive characteristic).
Function:
If the MDB switching signal input (X1996/Pin 9) is connected with this signal, torque/speed characteristic 1 (limited drive
characteristic 1) is activated. By activating the restricted drive characteristic 1, the drive characteristic is limited to speed restriction 1
which is programmable using MAN-cats II.
Factory setting:
1650 rpm at 100% torque
MDB 0 (plug-in connector X1996/pin 12)
Resistance-coded switching signal output for connecting torque/speed characteristic 0 (drive characteristic).
Function:
If the MDB switching signal input (X1996/Pin 9) is connected with this signal, torque/speed characteristic 0 (drive characteristic) is
activated.
Factory setting:
No restriction
EARTH (plug-in connector X1996/pin 13)
-UBat (earth) signal output, vehicle earth, same potential as the earth interpolation point on the central electrics system in the drivers cab.
Load:
max. 1.5 A
Function:
Earth supply for the required relays of the external connection
SPEED SIGNAL (plug-in connector X1996/pin 14)
Square-wave pulses with pulse duty factor 50:50. The angular momentum (number of pulses per revolution), the pulse duty factor as
well as a speed threshold from which the signal is output are programmable using MAN-cats II.
Load:
200mA; low-side driver
Function:
Speed information.
Useful for external control in order, for example, to be able to set a specic speed SET+ or SET- or for use as a release signal for a
unit belonging to the body.
Note:
The engine speed signal is not included in the standard delivery scope of the interface. Only possible with built-in KSM!
Interfaces TG - ZDR/FFR

10

HGB 1 (plug-in connector X1996/pin 15)

Resistance-coded switching signal output for connecting maximum speed limit 1.
Function:
If the HGB switching signal input (X1996/Pin 18) is connected with this signal, the maximum speed is limited to
the maximum speed limit 1 that is programmable using MAN-cats II.
HGB 2 (plug-in connector X1996/pin 16)
Resistance-coded switching signal output for connecting maximum speed limit 2.
Function:
If the HGB switching signal input (X1996/Pin 18) is connected with this signal, the maximum speed is limited to
the maximum speed limit 2 that is programmable using MAN-cats II.
HGB 3 (plug-in connector X1996/pin 17)
Resistance-coded switching signal output for connecting maximum speed limit 3.
Function:
If the HGB switching signal input (X1996/Pin 18) is connected with this signal, the maximum speed is limited to
the maximum speed limit 3 that is programmable using MAN-cats II.

HGB INPUT (plug-in connector X1996/pin 18)

Resistance-coded switching signal input for connecting different maximum speed limits.
Function:
By connecting the input with the standard external bridge (between X1996/Pin18 and 15), the maximum speed limit 1
(programmable using MAN-cats II) is activated.
If maximum speed limit 2 (programmable using MAN-cats II) is required, this must be activated by switching (switches, relays, etc.)
from HGB switching signal output 1 (X1996/Pin 15) to HGB-switching signal output 2 (X1996/Pin 16).
If maximum speed limit 3 (programmable using MAN-cats II) is required, this must be activated by switching (switches, relays, etc.)
from HGB switching signal output 1 (X1996/Pin 15) to HGB-switching signal output 3 (X1996/Pin 17).
Function release:
Immediately after activation
Note:
If the input remains unused for longer than 1 second or if a false or implausible signal is applied, this leads to an error entry
in the FFR control unit.
The HGB limits described here do not relate to the statutorily prescribed maximum speed limit for vehicles but to restrictions
that are technically necessary, for example, in connection with controlling the body, e.g. using power take-up.
HGB 1, 2 or 3 are only active with forward drive.

Interfaces TG - ZDR/FFR

11

Circuit diagram for X1996 with manual gearbox or automated gearbox

inside cab
terminal15

fuse
6A

60043
60525

40354

40141

40355

40142

60526

ZDR 4,5,6,7

60641

MDB

60524

ZDR 1,3,5,7

FFR

outside cab
X1996
1

FFR
NA1 switch
+UBAT
switch
NA1 display

Control in NA1 switch

FFR

+UBAT
FFR

+UBAT

NA2 switch
switch
NA2 display

Control in NA2 switch

+UBAT

ZDR 2,3,6,7
FFR

FFR

FFR
31016

3,09k

MDB 2

60534

10

31016

1,37k

MDB 1

60535

11

31016

511k

MDB 0

60530

12

31000

13

60105

14

FFR

KSM

FFR

FFR

31016

511k

HGB 0

60531

15

31016

1,37k

HGB 1

60533

16

31016

3,09k

HGB 2

60639

17

60523

18

HGB

Interfaces TG - ZDR/FFR

12

Circuit diagram for X1996 with automatic gearbox (ZF-HP)

inside cab
terminal 15

fuse
6A

60043
60525

40354

40141

40355

40142

ZDR 2,3,6,7

60526

ZDR 4,5,6,7

60641

MDB

60524

ZDR 1,3,5,7

FFR

outside cab
X1996
1

FFR
NA1 switch
+UBAT

Control in NA1 switch

87a

NA2 switch

30
85

FFR

+UBAT

87
86

FFR

+UBAT

FFR

Control in NA2 switch

87a
30
85

FFR

FFR

FFR

+UBAT

87
86

FFR

31016

3,09k

MDB 2

60534

10

31016

1,37k

MDB 1

60535

11

31016

511k

MDB 0

60530

12

31000

13

60105

14

FFR

KSM

FFR

FFR

31016

511k

HGB 0

60531

15

31016

1,37k

HGB 1

60533

16

31016

3,09k

HGB 2

60639

17

60523

18

HGB

Interfaces TG - ZDR/FFR

13

8.

List of interfaces and sites

ZDR-Interface
(FFR)
X1996/18-pin

view after removing the cover:

The complete interface consists of the 18-pin plug-in connector X1996.

This connector description is used on all circuit diagrams,
the connector in the drivers cab is colour-coded accordingly.
Access from outside by removing the cover.

Plug-in connection

Colour and

18-pin

coding

X1996

natural/4

Secondary locking for housing

Contacts (single goods / strip goods)

MAN part no.

Connector housing

Bushing housing

81.25475.0044

81.25435.0925

81.25475.0065

81.25435.0913

MAN part no.

Flat plug with notch 2.8 x 1/0.5-1

07.91202.0848 / 07.91202.0858

Flat plug with notch 2.8 x 2.5/1.5-2.5

07.91202.0849 / 07.91202.0859

Spring contact with notch 2.8 x 1/0.5-1

07.91201.0222 / 07.91201.0221

Spring contact with notch 2.8 x 2.5/1.5-2.5

07.91201.0224 / 07.91201.0223

Interfaces TG - ZDR/FFR

14

9.

Typical circuits

Typical circuit for triggering intermediate speed control 1

inside cab

outside cab

60043

X1996
1

60525

40354

40141

40355

40142

60526

60641

60524

60534

10

60535

11

60530

12

31000

13

60105

14

60531

15

60533

16

60639

17

60523

18

87a
30
85

87
86

+UBAT - switching signal input

depending on the enabling
conditions

Interfaces TG - ZDR/FFR

15

Typical circuit for triggering intermediate speed control 2

inside cab

outside cab

60043

X1996
1

60525

40354

40141

40355

40142

60526

60641

60524

60534

10

60535

11

60530

12

31000

13

60105

14

60531

15

60533

16

60639

17

60523

18

87a
30
85

87
86

+UBAT - switching signal input

depending on the enabling
conditions

Interfaces TG - ZDR/FFR

16

Typical circuit for triggering intermediate speed control 3

inside cab

outside cab

60043

X1996
1

60525

40354

40141

40355

40142

60526

60641

60524

60534

10

60535

11

60530

12

31000

13

60105

14

60531

15

60533

16

60639

17

60523

18

87a
30
85

87
86

+UBAT - switching signal input

depending on the enabling
conditions

Interfaces TG - ZDR/FFR

17

Typical circuit for triggering intermediate speed control 4

inside cab

outside cab

60043

X1996
1

60525

40354

40141

40355

40142

60526

60641

60524

60534

10

60535

11

60530

12

31000

13

60105

14

60531

15

60533

16

60639

17

60523

18

87a
30
85

87
86

+UBAT - switching signal input

depending on the enabling
conditions

Interfaces TG - ZDR/FFR

18

Typical circuit for triggering intermediate speed control 5

inside cab

outside cab

60043

X1996
1

60525

40354

40141

40355

40142

60526

60641

60524

60534

10

60535

11

60530

12

31000

13

60105

14

60531

15

60533

16

60639

17

60523

18

87a
30
85

87
86

+UBAT - switching signal input

depending on the enabling
conditions

Interfaces TG - ZDR/FFR

19

Typical circuit for triggering intermediate speed control 6

inside cab

outside cab

60043

X1996
1

60525

40354

40141

40355

40142

60526

60641

60524

60534

10

60535

11

60530

12

31000

13

60105

14

60531

15

60533

16

60639

17

60523

18

87a
30
85

87
86

+UBAT - switching signal input

depending on the enabling
conditions

Interfaces TG - ZDR/FFR

20

Typical circuit for triggering intermediate speed control 7

inside cab

outside cab

60043

X1996
1

60525

40354

40141

40355

40142

60526

60641

60524

60534

10

60535

11

60530

12

31000

13

60105

14

60531

15

60533

16

60639

17

60523

18

87a
30
85

87
86

+UBAT - switching signal input

depending on the enabling
conditions

Interfaces TG - ZDR/FFR

21

Typical circuit for triggering intermediate speed control 1, 2, ...., 7

inside cab

outside cab

60043

X1996
1

60525

40354

40141

40355

40142

60526

60641

60524

60534

10

60535

11

60530

12

31000

13

60105

14

60531

15

60533

16

60639

17

60523

18

87a
30
85

87
86

87a
30
85

87
86

+UBAT - switching signal input

depending on the enabling conditions
for ZDR1

+UBAT - switching signal input

depending on the enabling conditions
for ZDR2

87a
30
85

87
86

.... for ZDR3

87a
30
85

87
86

.... for ZDR4

87a
30
85

87
86

.... for ZDR5

87a
30
85

87
86

.... for ZDR6

87a
30
85

87
86

.... for ZDR7

Interfaces TG - ZDR/FFR

22

Typical circuit for triggering maximum speed control 2

inside cab

outside cab

60043

X1996
1

60525

40354

40141

40355

40142

60526

60641

60524

60534

10

60535

11

60530

12

31000

13

60105

14

60531

15

60533

16
87a

60639

60523

17

18

30
85

87
86

+UBAT - switching signal input

depending on the enabling
conditions
Interfaces TG - ZDR/FFR

23

Typical circuit for triggering maximum speed control 3

inside cab

outside cab

60043

X1996
1

60525

40354

40141

40355

40142

60526

60641

60524

60534

10

60535

11

60530

12

31000

13

60105

14

60531

15

60533

16
87a

60639

60523

17

18

30
85

87
86

+UBAT - switching signal input

depending on the enabling
conditions
Interfaces TG - ZDR/FFR

24

Typical circuit for triggering limited drive characteristic 1

inside cab

outside cab

60043

X1996
1

60525

40354

40141

40355

40142

60526

60641

60524

87a

60534

10

60535

11

60530

12

31000

13

60105

14

60531

15

60533

16

60639

17

60523

18

30
85

87
86

+UBAT - switching signal input

depending on the enabling
conditions

Interfaces TG - ZDR/FFR

25

Typical circuit for triggering limited drive characteristic 2

inside cab

outside cab

60043

X1996
1

60525

40354

40141

40355

40142

60526

60641

60524

87a

60534

10

60535

11

60530

12

31000

13

60105

14

60531

15

60533

16

60639

17

60523

18

30
85

87
86

+UBAT - switching signal input

depending on the enabling
conditions

Interfaces TG - ZDR/FFR

26