MANTED®

Guidelines
to fitting bodies



ZDR KSM


ZDR INTERFACE WITH CUSTOMER-SPECIFIC CONTROL MODULE (KSM) FOR EXTERNAL SPEED CONTROL IN TGA

PUBLISHER   MAN Nutzfahrzeuge AG   ESC Department

Engineering Services Consultation (formerly TDB)

Dachauer Str. 667   D - 80995 Munich

E-Mail: esc@man.eu   Fax: + 49 (0) 89 1580 4264


  1.        Area of application

  2.        Terms and abbreviations used

  3.        Applicable directives and standards

  4.        Addresses and responsibilities

  5.        General notes on the ZDR interface with KSM

  6.        Notes for the parameterisation of the KSM

  6.1.     Basic function for intermediate speed control

  6.2.     Parameterisation possibilities in the KSM

  7.        A-CAN interface

  7.1.    General

  7.2.     Parameterisation of the A-CAN

  7.3.     Information about the operational state of the vehicle on the A-CAN

  7.4.     Possible requirements for KSM via A-CAN

  7.5.     A-CAN transmission messages

  7.6.     A-CAN receipt messages

  7.7.     Processing KSM/FFR information if defined by the KSMA message

  8.       Pin description and circuit diagrams

  9.       Description of interfaces and installation location

  10.     Circuit examples



1.    Area of application

This interface description applies to all bodymakers who require "an external speed control" on MAN's commercial vehicles. The interface described here supplements the standard "ZDR interface with FFR" and thus adds numerous functions to this. Vehicles from the "Trucknology Generation" (TG) are affected by the interfaces as described here.


2.    Terms and abbreviations used

The following terms are terms or abbreviations are used in the PIN description:

Term/Abbreviation Explanation
A-CAN BodymakerCAN
AUS Switching off the FGR-/FGB-/ZDR-function
DBG Speed limitation
DE Digital input
EMV Electromagnetic compatibility
FFR Vehicle management computer
FGR/FGB/ZDR Speed control/speed restriction/intermediate speed control
GETRIEBE-N Gearbox in neutral position
HGB High speed limitation
HP ZF automatic gearbox HP...
KSM Customer-specific control module
KS Short circuit
LED Light emitting diode
M3135 MAN company standard (letter M + 4-digit number)
MAN-cats II Computer diagnosis system of MAN workshops
MBG Torque limitation
MEMORY Resumption of a stored function
NA Power take-off
PIN Plug-in contact
R-Gang Reverse gear
SET- Slow down or decrease the number of revs and set
SET+ Accelerate or increase the number of revs and set
SG Control unit
T-CAN Triebstrang-CAN (CAN = Controller Area Network)
+UBat Plus voltage of the batteries
-UBat Minus voltage of the batteries
ZDR Intermediate speed regulation/regulator


3.    Applicable directives and standards
   

  • The relevant guides to fitting bodies for trucks and semitrailer tractors, here in particular the "Electrics" and "Trucknology Generation" booklets; incl. all supplements in the bodymaker information sheets
  • MAN specification - relays for commercial vehicles
  • MAN standard M 3285 (EMC) and EC directive 72/245/EEC incl. 95/54/EEC
  • MAN standard M 3135 (electric lines)
  • DIN 40 050
  • DIN 40 839 part 1, 3 and 4
  • DIN 57 879, part 3
  • VDE 0879, part 3
  • VG 95 370 to 95 377
  • MIL-STO 461 and 462
  • ISO 11898-24V
  • SAE J1939/ff




4.    Addresses and responsibilities

The reference sources can be seen in the MAN guides to fitting bodies for trucks. This is available from:

MAN Nutzfahrzeuge AG / ESC Dept. (Fax: +49 089 1580 4264)
Postfach 50 06 20
D-80976 München


5.    General notes on the ZDR interface with KSM

   

  • The interface is not a standard feature of the vehicle and must be ordered separately.
  • MAN Sales must be informed of the desired parameters in the KSM control unit such as speed limitation, torque limitation etc. for the programming in the plant when the order is placed.
  • The preparation for "Start-Stop device" is independent from the interface for external speed control and must be ordered separately.
    The lines for an external control (engine start-stop) are in a coil in the frame end.
  • The "backup locking for refuse trucks" is not a part of the interface and must be ordered separately.
  • The interface wiring must be treated with extreme care since it involves major intervention in the on-board network and in the wiring of the electronics.
  • Only electric lines corresponding with MAN's M 3135 standard may be used.
  • Only relays corresponding with MAN's relay specifications for external wiring may be used.
  • Care must be taken that the contacts are properly crimped in accordance with the instructions of the contact manufacturer.
  • External control elements of the bodymaker must comply with the protective system IP69K in accordance with DIN 40 050 and must additionally be secured against unauthorised intervention by third parties.
  • The electricity supply (+UBAT) for units and controls on the body is to be fed from the battery via a separate and suitable line fuse protection system. The feeding of just +12 volt to just one battery is not permissible.
  • For the ground a separate cable is to be laid to the joint ground point on the engine bearing (the vehicle frame must not be misused as a ground lead!).
  • Different ground potentials of the external wiring must not be connected to each other.
  • The wiring of the interface must be decoupled from the load current circuit of the body control.
  • The external wiring must comply with the requirements of MAN's M 3285 standard for the commercial vehicle system. For example, radio devices such as radio remote control must not influence any functions described in the specifications.
  • The wiring examples issued by MAN as illustrations are under no circumstances to be used as design instructions. Whoever wires the interface is fully liable in this respect.




6.    Notes for the parameterisation of the KSM


6.1.    Basic function for intermediate speed control

  • The parameterisation of the individual ZDR modes is carried out in the FFR. The individual modes can be selected externally (outside the cab) via the standard ZDR interface (FFR).
  • The parameterisation possibilities of the FFR and the pin description of the "ZDR interface with FFR" are described in the document "ZDR interface with the vehicle management computer for external speed control in TG".
  • With the "ZDR interface with KSM" the "SET+", "SET-", "MEMORY" and "OFF" functions already known from the cruise control system are made available externally (outside the cab).
  • In addition further intermediate speeds can be realised - by means of the activation of the speed limitation.




6.2.    Parameterisation possibilities in the KSM

Various functions can be parameterised in the KSM with the aid of MAN-cats II:
   

  • Speed limitation:
    When the corresponding DBG pins (X1997/pin 1 and 2) are activated the parameterised speed limitation is selected.
  • Torque limitation:
    When the corresponding MBG pins (X1997/pin 3 and 4) are activated the parameterised torque limitation is selected.
  • Engine speed:
    That angular impulse figure (number of impulses per engine revolution) and the speed threshold from which the rectangular signal (duty cycle 50/50) is given can be parameterised.
  • ZDR digital inputs:
    Parameterisation is possible if the inputs (SET+/-, MEMORY and OFF) are supported. If the inputs are supported any corresponding specification by A-CAN is ignored. If the inputs are not supported any specification by A-CAN is passed on and a possible wiring of the digital inputs ignored.
  • A-CAN interface:
    For parameterisation possibilities see chapter 7.2.
 
  • Fault recognition at the following switch signal outputs:
    • High-side switches
      • Parking brake (X1997/Pin 5)
      • Brake (X1997/Pin 6)
      • R_gear (X1997/Pin 7)
      • Clutch (X1997/Pin 8)
      • Check lamp (X1997/Pin 10)
      • Tank warning (X1997/Pin 11)
      • Readiness for operation (X1997/Pin 12)
    • Low-side switch
      • Gearbox N (X1997/Pin 9)
    • The following variants are possible in the fault recognition:
    • Without fault recognition
      Switch signal output is not monitored
    • With fault recognition
      • ==> Monitoring of high-side switches:
        Signal high: short circuit to ground is monitored
        Signal low: short circuit to +UBAT and line interruption are monitored
      • ==> Monitoring of low-side switches:
        Signal high: short circuit to ground and line interruption are monitored
        Signal low: short circuit to +UBAT is monitored
    • With fault recognition and test impulses ("extended fault monitoring")
      • ==> Test impulses during KSM system start (up to approx. 3 seconds after "terminal 15 on")
        During the system start short circuit to +UBAT, short circuit to ground and line interruption are monitored following which faults are monitored depending on the version of the switch signal output
      • ==> Test impulses
        Independent of the version of the switch signal output, from "terminal 15 on" short circuit to +UBAT, short circuit to ground and line interruption are monitored.
    • Condition for fault recognition:
      Load at output for high-side switches not higher than 400Ω and at low-side switches not higher than 2000Ω.
      Note:
      If the fault recognition is activated the diagnostic depth of the components connected to the "ZDR interface with the KSM" is considerably improved and hence the functional safety and vehicle availability are increased.

Fault recognition with differing parameterisation using the "R-gear" switch signal output as an example:

  • Output not supported (load is connected):
    Fault recognition not active





•    Output supported (load must be connected!):
Fault recognition active: current state of the output is monitored



•    Output is supported (load must be connected!):
Fault recognition active: current state of the output is monitored and test impulses only during at KSM control unit run up (test of ground short circuit with high-side switches and test of Ubat short circuit on low-side switches)



•    Output supported (load must be connected!):
Fault recognition active: current state of the output is monitored and test impulses cyclical (permanent monitoring on ground short circuit with high-side switches and permanent monitoring on Ubat short circuit with low-side switches)



Note:
The test impulses have a duration of approx. 1 ms and a repetition time of approx. 300 ms.Caution:
The switch signal outputs of the KSM are activated by CAN messages which are transmitted on the T-CAN to the KSM. If there is no CAN message the related signal output of the KSM switches into a defined condition:High-side switch: lowLow-side switch: high



7.    A-CAN interface


7.1.    General

A high-speed CAN interface to ISO 11898-24V and specification 2.0B is available for the communication to the bodymaker CAN. The transmission speed is 250kbit/s.
The A-CAN is completely galvanically separated to protect the MAN CAN network in the vehicle from external influences/interference.
A 120W terminating resistor is permanently connected. There is a CAN filter reactor.
The CAN data line is designed as a 2-core twisted line up to the interface (MAN parts number: 07.08132.4384). For EMC reasons the line from the interface to the control unit on the body should be as short as possible and twisted (see ISO 11898-24V). MAN recommends the line with the MAN item number 07.08132.4384 (FLRY-2x0,75-B-28-or-bror) for this.
MAN bases its definition of the A-CAN on the SAE J1939/ff.
The numbers in brackets beside the identification number refer to SAE J1939/71 "VEHICLE APPLICATION LAYER".


7.2.    Parameterisation of the A-CAN

Each message which the KSM receives on the T-CAN is also transmitted to the A-CAN. It can be parameterised so that individualor all A-CAN messages are not transmitted. It can be paramaterised whether a message which is received (KSMA) is ignored by the body electronics in the KSM or processed.
The receiving timeout can also be parameterised; if applicable also the identifier of the message received.


7.3.    Information about the operational state of the vehicle on the A-CAN

The following information with regard to the body electronics can be made available via the A-CAN – depending on the fittings of the vehicle and the parameterisation in the KSM:

  • Driveline open/closed
  • Gearbox output speed
  • Gearbox input speed
  • Clutch slip
  • Gear selected
  • Ratio of gearbox input -
    to gearbox output speed
  • Current/last gear
  • Gear engaged
  • Gearbox neutral position
  • NA1 requested/active
  • NA2 requested/active
  • Parking brake activation
  • Vehicle speed
  • Clutch pedal activation
  • Brake pedal activation
  • ABS active/not active
  • Brake pedal position
  • Reverse gear engaged/
    not engaged
  • Engine torque/injection quantity
  • Engine speed
  • Kickdown position
  • Idle position
  • Degree of engine utilisation
  • Accelerator position
  • Engine oil pressure
  • Coolant temperature
  • Fuel temperature
  • Engine oil temperature
  • Parking brake and/or trailer supply air pressure
  • Brake circuit 1 and 2
  • Supply pressure for auxiliary (special) equipment
  • Air pressure (surroundings)
  • Air temperature (surroundings)
  • Time/date
    (GMT = "General Mean Time")
  • Total kilometrage
  • Daily kilometre recorder




7.4.    Possible requirements for KSM via A-CAN

KSM can receive the following requirements from the body electronics on the A-CAN for further processing by the FFR:

•    Torque requirement/torque limitation
•    Speed requirement/speed limitation
•    Request for the intermediate speed control ZDR mode S, 1-7
•    Request for ZDR operation (SET+/-, MEM, AUS)
•    Maximum speed limitation
•    External engine start/stop (currently [2/01] only engine stop possible!)


7.5.    A-CAN transmission messages

The following transmission messages can be provided by KSM on the A-CAN:ETC1:

Electronic Transmission Controller #1 (3.3.5 = chapter of SAE J1939/ff)      0CF00203 

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
10 ms 8 bytes 240 2 3 0x00F002 0x0CF00203


Byte Bit Description
1 8 to 3 XX (non-essential information for body constructor)
2 and 1 ETC1 [driveline_engaged] (3.2.2.6)
00 (Driveline disengaged)
01 (Driveline engaged)
10 (error)
11 (not available)
2 and 3 --- [output_speed_TCU] (3.2.1.14)
rpm per bit = 0,125 Offset [rpm] = 0 Range [rpm] = 0 to 8031,875
4 --- [clutch_slip] (3.2.1.20)
% per bit = 0,4 Offset [%] = 0 Range [%] = 0 to 100
5 --- XX
6 and 7 --- [input_speed] (3.2.5.55)
rpm per bit = 0,125 Offset [rpm] = 0 Range [rpm] = 0 to 8031,875
8 --- XX


ETC2: Electronic Transmission Controller #2 (3.3.8)                                                                                                                       18F00503

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
100 ms 8 bytes 240 5 6 0x00F005 0x18F00503

Byte Bit Description
1 --- [selected_gear] (3.2.1.23)
2 and 3 --- l [actual_gear_ratio] (3.2.1.25)
0,001 per Bit Offset = 0 Range = 0 ... 64,255
4 --- [current_gear] (3.1.2.22)
5 to 8 --- XX

Note:

Offset = -125 Range = -125 ... 125
Values with a positive sign represent forward gears, values with a negative sign reverse gears. The value “0” is used for gearbox neutral, the value “126” for the “Park” position (automatic transmissions).


ETC3: Electronic Transmission Controller #3 (3.3.50)                                         1CFEC703

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
Every second, or on status change 8 bytes 254 199 7 0x00FEC7 0x1CFEC703


Byte Bit Description
1 and 2 --- XX
3 8 to 5 XX
4 and 3 ( Engagement indicator) [shift_finger_status_1] (3.2.6.20)
00 aus (off)
01 an (on)
10 (error)
11 (not available)
2 and 1 (Neutral indicator) (3.2.6.19)
00 (off)
01 (on)
10 (error)
11 (not available)
4 to 6 --- XX
7 8 and 7 not defined
6 to 4 [PTO2_state]
0x1 (requested)
01x (activ)
1xx not defined
3 to 1 [PTO1_state]
0x1 (requested)
01x (activ)
1xx not defined
8 --- XX


Note:
The power takeoff status is not defined in accordance with SAE 1939/71.


Ccveh_speed: Cruise control/vehicle speed (3.3.31) 18FEF100

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
100 ms 8 bytes 254 241 6 0x00FEF1 0x18FEF100


Byte Bit Description
1 8 to 5 XX
4 and 3 [park_brake_switch] (3.2.6.8)
00 (Parking brake not set)
01 (Parking brake set)
10 (error)
11 (not available)
2 and 1 XX
2 and 3 --- Fahrzeuggeschwindigkeit [veh_speed_FFR] (3.2.1.12)
km/h per Bit = 1/256 Offset [km/h] = 0 Range [km/h] = 0  ...  251
4 8 and 7 [clutch_switch] (3.2.6.12)
00 (Clutch pedal released)
01 (Clutch pedal depressed)
10 (error)
11 (not available)
6 and 5 [brake_switch] (3.2.6.11)
00 (Brake pedal released)
01 (Brake pedal depressed)
10 (error)
11 (not available)
4 to 1 XX
5 to 8 --- XX


EBC1: Electronic Brake Controller #1 (3.3.4) 18F0010B

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
100 ms 8 bytes 240 1 6 0x00F001 0x18F0010B


Byte Bit Description
1 8 and 7 XX
6 and 5 [ABS_active] (3.2.2.9)
00 (ABS passive but installed)
01 (ABS active)
10 (reserved)
11 (don’t care)
4 to 1 XX
2 --- (Brake pedal position) [BP_position] (3.2.1.18)
0,4% per Bit Offset = 0 % Range = 0% ... 100%
3 to 8 --- XX


AUX_STAT_ZBR1: Auxiliary state I/O body controller #1 0x18FFA121

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
Every second, or on status change 8 bytes 255 161/A1hex 6 0x00FFA1 0x18FFA121

Byte Bit Description
1 8 and 7 Reverse gear engaged
00 (off)
01 (on)
10 (error)
11 (not available)
6 and 5 Info fuel level too low in current tank
00 (off)
01 (on)
10 (error)
11 (not available)
4 to 1 XX
2 8 to 3 XX
2 and 1 Info NOT-OFF
00 (off)
01 (on)
10 (error)
11 (not available)
3 to 8 -- XX

EEC1: Electronic engine controller #1 (3.3.7) 0CF00400

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
Der FFR sendet die EEC1 alle 10 ms. SAE 12-50ms 8 bytes 240 4 3 0x00F004 0x00F00400


Byte Bit Description
1 and 2 --- XX
3 --- (Actual engine torque) [act_eng_torque] (3.2.1.5)
1% per Bit Offset = -125 % Range = -125% ... 125%
4 and 5 --- (Engine speed) [engine_speed] (3.2.1.9)
0,125 rpm per Bit Offset = 0 rpm Range = 0 rpm ... 8031,875 rpm
6 to 8 --- XX

EEC2: Electronic engine controller #2 (3.3.6) 0CF00300

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
50 ms 8 bytes 240 3 3 0x00F003 0x00F00300


Byte Bit Description
1 8 to 5 (not defined)
4 bis3 (AP kickdown switch) [AP_kickdown_sw] (3.2.2.5)
00 (Kickdown passive)
01 (Kickdown active)
10 (error)
11 (not available)
2 and 1 (AP low idle switch) [AP_low_idle_sw] (3.2.2.4)
00 (AP not in low idle condition)
01 (AP in low idle condition)
10 (error)
11 (not available)
2 --- (Accelerator pedal (AP) position) [AP_position] (3.2.1.8)
0,4 % per Bit Offset = 0 % Range = 0% ... 100%
3 --- (Load at current speed) [load_curr_speed] (3.2.1.7)
1 % per Bit Offset = 0 % Range = 0% ... 100%
4 to 8 --- XX


EngFlui_LevPre: Engine fluid level/pressure (3.3.29)  18FEEF00

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
500 ms 8 bytes 254 239 6 0x00FEEF 0x00FEEF00


Byte Bit Description
1 to 3 --- XX
4 --- (Engine oil pressure) [eng_oil_press] (3.2.5.28)
40 mbar per Bit Offset = 0 mbar Range = 0 bar ... 10 bar
5 to 8 --- XX


Eng_Temp: Engine Temperature (3.3.28) 18FEEE00

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
1 s 8 bytes 254 238 6 0x00FEEE 0x00FEEE00


Byte Bit Description
1 --- (Engine coolant temperature) [eng_cool_temp] (3.2.5.5)
1 °C per Bit Offset = -40 °C Range = -40 °C ... 210 °C
2 --- (Fuel temperature) [fuel_temp] (3.2.5.14)
1 °C per Bit Offset = -40 °C Range = -40 °C ... 210 °C
3 and 4 --- (Engine oil temperature) [eng_oil_temp] (3.2.5.15)
0.03125 °C per Bit Offset = -273 °C Range =  -273°C ... 1735°C
5 to 8 --- XX


ECAM1:Supply pressure 3.3.75 (ECAM1)  18FEAE30

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
1 s 8 bytes 254 174 6 65,198 0x18FEAE30


Byte Bit Description
1 --- SAE: Pneumatic supply pressure (by MAN not used) [pneu_supply_press]
2 --- SAE: Parking and /or trailer air pressure (MAN: circuit 3 {23}) [park_trailer_press]
3 --- SAE: Service brake air pressure, circuit #1 (MAN: circuit 1 {21}) [serv_brake_press1]
4 --- SAE: Service brake air pressure, circuit #2 (MAN: circuit 2 {22}) [serv_brake_press2]
5 --- SAE: Auxiliary equipment supply pressure (MAN: circuit 4 {24}) [aux_equip_press]
6 --- SAE: Air suspension pressure (MAN: pilot circuit) [air_susp_press]
7 to 8 --- XX


Note:

MAN: Byte 6 does not show the air suspension pressure
Resolution for Byte 1 to 6
80 mbar per bit Offset = 0 mbar Range = 0 bar ... 20 bar


Amb_Cond: Ambient conditions (3.3.35) 18FEF500

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
1 s 8 bytes 254 254 6 0x00FEF5 0x00FEF500


Byte Bit Description
1 --- (Barometric pressure) [barometric_press] (3.2.5.43)
5 mbar per Bit Offset = 0 mbar Range = 0 ... 1,25 bar
2 and 3 --- XX
4 and 5 --- (Ambient air temperature) [amb_air_temp] (3.2.5.12)
0.03125 °C per Bit Offset = -273 °C Range = -273 ... 1735.0°C
6 to 8 --- XX


Time_Date: Time /Date  (3.3.20) 18FEE6EE

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
1 s 8 bytes 254 230 6 FF0A 18FEE6EE


Byte Bit Description
1 --- (Seconds) [seconds] (3.2.5.93)
0,25 s per Bit Offset = 0 s Range = 0 ... 59,75 s
2 --- (Minutes) [minutes] (3.2.5.94)
1 min per Bit Offset = 0 min Range = 0 ... 59 min
3 --- (Hours) [hours] (3.2.5.110)
1 h per Bit Offset = 0 h Range = 0 ... 23 h
4 --- (Month) [month] (3.2.5.112)1
1 Monat per Bit Offset = 0 Months Range = 0 ... 12 Months
5 --- Tag (Day) [day] (3.2.5.111)2
0,25 Tage per Bit Offset = 0 Days Range = 0 ... 31,75 Days
6 --- (Year) [year] (3.2.5.113)
1 Jahr per Bit Offset = +1985 Years Range = 1985 ... 2235 Years
7 --- (Local Minute Offset) (3.2.5.296)
1 min per Bit Offset = -125 min Range = von –59min to +59 min
8 --- (Local Hour Offset) (3.2.5.297)
1 h per Bit Offset = -125 h Range = von –23 h to +23 h


1 The value "0" is not used. The value "1" corresponds with month "January", the value "2" with the month "February" etc.
2 The value "0" is not used. The value 1 to 4 (0.25 days/bit) correspond with the first day of the month, the values 5 to 8 with the second day of the month etc.

Veh_dist: Vehicle Distance high resolution (3.3.54)  18FEC1EE

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
1 s 8 bytes 254 193 6 FEC1 18FEC1EE


Byte Bit Description
1 to 4 --- (High resolution total vehicle distance) [tot_veh_dist] (3.2.5.106)
5 m per Bit Offset = 0 m Range = 0 ... 21 055 406 km
5 to 8 --- (High resolution trip distance) [trip_distance] (3.2.5.107)
5 m per Bit Offset = 0 m Range = 0 ... 21 055 406 km




7.6.    A-CAN receipt messages

The following receipt message can be processed by KSM and passed on to the FFR:KSMA:

Customer-specific control module – body 0CEFFD55

Transmission repetition rate Data length PDU format PDU specific Defaultpriority Parameter group number Identifier
10 ms 8 bytes 1 destination address

KSM = FDhex

 3 Proprietary A: EF00 0C EF FD 55


Byte Bit Description
1 8 and 7 (not defined)
6 and 5 Override control mode priority [ksma_ocmp] (3.2.3.3) not supported
4 and 3 Requested speed control conditions [ksma_rscc] (3.2.3.2) not supported
2 and 1 Override control mode [ksma_ocm] (3.2.3.1)
00 (Override disabled)
01 (speed control)
10 (torque control)
11 (speed/torque control)
2 and 3 --- Requested speed/Speed limit [ksma_req_speed] (3.2.1.19)
0,125 rpm per Bit Offset = 0 rpm Range = 0 ... 8031.875 rpm
4 --- Requested torque/Torque limit [ksma_req_torque] (3.2.1.15)
1 % per Bit Offset = -125 % Range = -125% ... 0%
5 --- Requested road speed limit [ksma_HGB]
1 km/h per Bit Offset = 0 km/h Range = 0 km/h ... 250 km/h
6   ZDR [ksma_sw_status]
Values described in SAE J1939/ff
8 and 7 Cruise control accelerate switch (3.2.6.17)
6 and 5 Cruise control resume switch (3.2.6.16)
4 and 3 Cruise control coast switch (3.2.6.15)
2 and 1 Cruise control set switch (3.2.6.14)
By MAN
00000000 Neutral
00000001 Off
00000100 Set -
00010000 restart
01000000 Set +
10101010 Defect
7 8 to 5 ZDR Mode request [ZDR_mode_req]
0000 Mode S
0001 Mode 1
0010 Mode 2
0011 Mode 3
0100 Mode 4
0101 Mode 5
0110 Mode 6
0111 Mode 7
1000 ZDR switch off
1001 (reserved)
1010 (reserved)
1011 (reserved)
1100 (reserved)
1101 (reserved)
1110 (reserved)
1111 (not available)
4 and 3 Motor Stop [ksma_MotorStop]
00 (no request)
01 Motor Stop
10 (reserved)
11 (don’t care/take no aktion)
2 to 1 Motor Start [ksma_MotorStart]
00 (no request)
01 Motor Start
10 (reserved)
11 (don’t care/take no aktion)
8 --- XX



7.7.    Processing KSM/FFR information if defined by the KSMA message

The override control mode (ocm) of the KSMA message (KSMA_ocm) is crucial for the processing of speed and torque. The following description (case 1-4) explains how the KSMA_ocm is generated from the KSMA_ocm. KSM1 is the T-CAN message from the KSM to the FFR. The ocm=11 (speed/torque limit control) of the KSM1 message is supported by the FFR as standard. The processing of the modes ocm=01 (speed control) and ocm=10 (torque control) of the KSM1 message is not active in the FFR but can if required be released in the FFR.

1. KSMA_ocm=11 → KSM1_ocm=11 (Speed/torque limit control):

•    Limitations (KSMA) are linked with the digital inputs (torque and speedl) so that in each case the smallest value can be used as the KSM1 message

•    ZDR S request, 1-7 is passed on via KSM1: Activation in the FFR in dependence on the switch-off conditions parameterised in the FFR
•    ZDR operation request (SET+/-, MEM, AUS) via KSMA or via the digital inputs of the KSM – depending on the parameterisation in the KSM – is passed on via KSM1: version in the FFR

2. KSMA_ocm=01 → KSM1_ocm=01 (Speed control):
  

  • Speed target value definition possible, limitation in KSM1 by digital inputs "speed limitation" KSM possible
  • Torque limitations (KSMA) are linked with the digital inputs "torque limitation" so that in each case the smallest value are used as the KSM1 message
  • ZDR S request, 1-7 is passed on via KSM1:
    Only the switch-off conditions parameterised in the relevant ZDR mode and the parameterised standard parameter kit is then processed by FFR. The upper/lower speed limit parameterised in the relevant ZFR mode and the speed target value parameterised in the FFR are then ignored.



      3. KSMA_ocm=10 → KSM1_ocm=10 (Torque control):
         

      • Torque target value definition possible, limitation in KSM1 by digital inputs "torque limitation" KSM possible
      • Speed limitations (KSMA) are linked with the digital inputs "speed limitation so that in each case the smallest value is used as the KSM1 message



        4. KSMA_ocm=00 → KSM1_ocm=11(Speed/torque limit control):

        • No processing/forwarding of KSMA/Byte 2, 3, 4
        • Torque limitation via the digital inputs "torque limitation" to KSM possible
        • Speed limitations via the digital input "speed limitation" to KSM possible
        • ZDR S request, 1-7 is passed on via KSM1:
          Activation in the FFR in dependence on the switch-off conditions parameterised in the FFR
        • ZDR operation request (SET+/-, MEM, AUS) via KSMA or via the digital inputs of the KSM
          – depending on the parameterisation in the KSM – is passed on via KSM1: implemented in the FFR



                The general rule is:

                • ZDR mode selection via CAN has priority over the ZDR pins of the FFR
                • ZDR operation via CAN has priority over cruise control controls
                • Limitations are linked in the KSM and FFR so that in each case the smallest value is used as the KSM1 message
                • Definitions are limited to limitations
                • KSMA message parameterised to "not receiving"->

                        → KSM1_ocm=11

                        Caution:
                        If an input value of the A-CAN is not valid (e.g. in event of bus-off, failure of KSMA message), this has a direct effect, i.e. no "old" A-CAN information is frozen (example: previously requested limitations are no longer active or effective).


                        8.    Pin description and circuit diagrams

                        DBG 1+3 (plug connection X1997/Pin 1)

                        +UBat switch signal input for the triggering of speed limitation 1 and 3Function:
                        If the input is wired with +UBat (ready for operation; X1997/pin 12) the engine speed is limited to "speed limitation 1" which can be parameterised with the aid of MAN cats II.
                        If +UBat is taken away the selected "speed limitation 1" is cancelled again.
                        If at the same time the input DBG 2+3 (X1997/pin 2) is wired with +UBat (ready for operation; X1997/pin 12) the engine speed is limited to "speed limit 3" parameterised with the aid of MAN-cats II.
                        If +UBat is taken away from both inputs the selected "speed limitation 3" is cancelled again.
                        This function is also useful as a further intermediate speed with which an initially higher set speed is limited.Function release:
                        As soon as +UBat (ready for operation or terminal 15 FFR) is applied.

                        DBG 2+3 (plug connection X1997/Pin 2)

                        +UBat switch signal input for the triggering of the speed limitation 2 and 3Function:
                        If the input is wired with +UBat (ready for operation; X1997/Pin 12) the engine speed is limited to "speed limitation 2" which can be parameterised with the aid of MAN-cats II.
                        If +UBat is taken away the selected "speed limitation 2" is cancelled again.
                        If at the same time the input DBG 1+3 (X1997/pin 1) is wired with +UBat (ready for operation; X1997/pin 12) the engine speed is limited to "speed limitation 3" which can be parameterised with the aid of MAN-cats II.
                        If +UBat is taken away from both inputs the selected "speed limitation 3" is cancelled again.
                        This function is also useful as a further intermediate speed with which an initially higher set speed is limited.

                        Function release:
                        As soon as +UBat (ready for operation or terminal 15 FFR) is applied.

                        MBG 1+3 (plug connection X1997/Pin 3)

                        +UBat switch signal input for the triggering of torque limitation 1 and 3Function:
                        If the input is wired with +UBat (ready for operation; X1997/pin 12) the torque of the engine is limited to "torque 1" which can be parameterised with the aid of MAN-cats II.
                        If +UBat is taken away the selected "torque limitation 1" is cancelled again.
                        If at the same time the input MBG 2+3 (X1997/pin 4) is wired with +UBat (ready for service; X1997/pin 12) the torque of the engine is limited to "torque limitation 3" which can be parameterised with the aid of MAN-cats II.
                        If +UBat is taken away from both inputs the selected "torque limitation 3" is cancelled again.
                        This function is useful to protect units connected with the body from too high a torque from the engine.Function release:
                        As soon as +UBat (ready for operation or terminal 15 FFR) is applied.


                        MBG 2+3 (plug connection X1997/Pin 4)

                        +UBat -switch signal input for the triggering of the torque limitation 2 and 3Function:
                        If the input is wired with +UBat (ready for operation; X1997/pin 12) the torque of the engine is limited to "torque limitation 2" which can be parameterised with the aid of MAN-cats II.
                        If +UBat is taken away the selected "torque limitation 2" is cancelled again.
                        If at the same time the input MBG 1+3 (X1997/pin 3) is wired with +UBat (ready for operation; X1997/pin 12) the torque of the engine is limited to "torque limitation 3" which can be parameterised with the aid of MAN cats II.
                        If +UBat is taken away from both inputs the selected "torque limitation 3"is cancelled again.
                        This function is useful to protect units connected with the body from too high a torque from the engine.

                        Function release:
                        As soon as +UBat (ready for operation or terminal 15 FFR) is applied.


                        PARKING BRAKE (plug connection X1997/pin 5)
                        +UBat -switch signal output. If a load is connected and the parking brake is not activated a low level of Ulow<2V sets itself.Load:
                        max. 500mAFunction:
                        Information that the parking brake is engaged. Useful for the release of a function to prevent undesirable outside intervention on controls outside the cab.Caution:
                        To ensure that short circuits and line interruption are reliably recognised if loads are connected and fault recognition is activated the connected load must be <400Ω.
                        BRAKE (plug connection X1997/pin 6)
                        +UBat -switch signal output. If a load is connected and the brake is not activated a low level of Ulow<2V sets itself.Load:
                        max. 500mAFunction:
                        Information that the brake is activated. Useful for the release of a function to prevent undesirable outside intervention on controls outside the cab.Caution:
                        To ensure that short circuits and line interruption are reliably recognised if loads are connected and fault recognition is activated the connected load must be <400Ω

                        R-gear (plug connection X1997/pin 7)
                        +UBat switch signal output. If a load is connected and the parking brake is not activated a low level of
                        Ulow<2V sets itself.Load:
                        max. 500mAFunction:
                        Information, that the reverse gear is engaged. Useful for example for shifting to a lower maximum speed limitation (HGB2) in reverse gear or also for reversing lock for refuse trucks.Caution:
                        To ensure that short circuits and line interruption are reliably recognised if loads are connected and fault recognition is activated the connected load must be <400Ω.
                        CLUTCH (plug connection X1997/pin 8)
                        +UBat switch signal output. If a load is connected and the clutch is not activated a low level of Ulow<2V sets itself.Load:
                        max. 500mAFunction:
                        Information that the clutch is engaged. Useful for the release of a function to prevent unwelcome outside intervention on controls outside the cab.Caution:
                        To ensure that short circuits and line interruption are reliably recognised if loads are connected and fault recognition is activated the connected load must be <400Ω.
                        GEARBOX N (plug connection X1997/pin 9)
                        -UBat switch signal output. If the gear is engaged the high level (approx. +UBat) sets itself.Load:
                        max. 300mAFunction:
                        Information that the gearbox is in neutral position. Useful for the release of a function in dependence of the gearbox neutral position (no gear engaged).

                        Caution:
                        To ensure that short circuits and line interruption are reliably recognised if loads are connected and fault recognition is activated the connected load must be <2kΩ. If the fault recognition is activated the connected load must be connected after terminal 15 FFR (X1996/pin 1). "Ready for operation" (X1997/pin 12) must not be used if "ready for operation" is used instead of terminal 15 . If "ready for operation" is used instead of terminal 15 FFR and in this way if the fault recognition is activated fault memory entries are already made during the system start (monitoring already active during the system start stage but not ready for operation until active following the system start stage).
                        CHECK LAMP (plug connection X1997/pin 10)
                        +UBat switch signal output. If a load is connected and the KSM-SG or the connected periphery is in a faultfree condition a low level of Ulow<2V sets itself.Load:
                        max. 600mAFunction:
                        Information that interference has arisen in the KSM-SG or in its connected periphery.Caution:
                        To ensure that short circuits and line interruption are reliably recognised if loads are connected and fault recognition is activated the connected load must be <400Ω. When the control unit is running up the output will then be automatically triggered for approx. 3 seconds (light bulb test).
                        TANK WARNING (plug connection X1997/pin 11)
                        +UBat switch signal output. If a load is connected and the tank is full enough a low level of Ulow<2V sets itself.Load:
                        max. 600mAFunction:
                        Information that there is still approx. 20% of the maximum fuel content of the tank. This information is also displayed at the same time on the instruments with the information "FILL UP".Caution:
                        To ensure that short circuits and line interruption are reliably recognised if loads are connected and fault recognition is activated the connected load must be <400Ω. When the control unit is running up the output will then be automatically triggered for approx. 3 seconds (light bulb test).
                        READY FOR OPERATION (plug connection X1997/pPin 12)
                        +UBat switch signal output. The final stage switches to high approx. 3 sec after terminal 15 is "on". If a load is connected and KSM-SG is not (yet) in a ready-for-operation state a low level of Ulow<2V sets itself.Load:
                        max. 2AFunction:
                        Information that the KSM-SG is ready for operation. Useful for the release of a function. The signal is still issued approx. 2 secs after terminal 15 "OFF" to permit any run up of a control unit which may be necessary with a connected body electronics.Caution:
                        To ensure that short circuits and line interruption are reliably recognised if loads are connected and fault recognition is activated the connected load must be <400Ω. After the system start (approx. 3sec.) the output is then triggered.

                        SET+ (plug connection X1997/pin 13)
                        +UBat switch signal input for the triggering of the function "increase speed"Function:
                        Increase speed.
                        If the input is wired with +UBat (ready for operation; X1997/pin 12) the engine speed runs continuously towards the upper speed limit.
                        If the activation is interrupted the engine control controls the current speed.
                        The upper speed limit can be:
                        • the final speed of the engine,
                        • the upper speed limit in ZDR S, ZDR 1,...., ZDR 7 which can be parameterised with the aid of MAN-cats II.
                        • the speed limitation which can be parameterised and activated with the aid of MAN-cats II in the FFR or KSM.
                        The set speed is switched off, i. e. the engine goes to idle speed (ZDR S) or the "lower speed limit" (ZDR 1, . . . . , ZDR 7) by "opening" the standard bridge between "ready for operation" (X1997/pin 12) and "OFF" (X1997/pin 15).Function release:
                        Approx. 3.5secs after terminal 15 is "on" the function can be activated by wiring with +UBat (ready for operation or terminal 15 FFR).
                        SET- (plug connection X1997/pin 14)
                        +UBat switch signal input for the triggering of the function "lower speed".Function:
                        Lower speed.
                        If the input is wired with +UBat (ready for operation; X1997/pin 12) the set engine speed runs continuously up to the idle speed (ZDR S) or the lower speed limit (ZDR 1, . . . . , ZDR 7). If the activation is interrupted the engine control controls the current speed.
                        The set speed is switched off , i. e. the engine goes to idle speed (ZDR S) or the "lower speed" (ZDR 1, . . . , ZDR 7) by "opening" the external bridge between "ready for operation" (X1997/pin 12) and "OFF" (X1997/pin 15).Function release:
                        Approx. 3.5secs after terminal 15 is "on" the function can be activated by wiring with +UBat (ready for operation or terminal 15 FFR).
                        OFF (plug connection X1997/pin 15)
                        +UBat switch signal input for the release/switch off of the ZDR functions.Function:
                        If the input is wired with +UBat (ready for operation; X1997/pin 12) the ZDR functions are released. The ZDR functions are switched off by "opening" the external bridge between "ready for operation" (X1997/pin 12) and "OFF" (X1997/pin 15).Caution:
                        If there is no external bridge between X1997/pin 12 and X1997/pin 15 the "OFF" function is permanently activated, i.e. activation of the ZDR functions is not possible.
                        MEMORY (plug connection X1997/pin 16)
                        +UBat -switch signal input for the resumption/storing of a speed.Function:
                        If the input is wired with +UBat after the end of the pulse signal the engine runs on the ZDR S, ZDR 1, ...., ZDR 7 which can be programmed with the aid of MAN-cats II and regulates this. After changing this by e. g. "SET+" or "SET-" the new speed can be stored by wiring the input with +UBat (t³ 2sec.).
                        The set speed is switched off, i.e. the engine goes to the idle speed (ZDR S) or the lower speed limit (ZDR 1, . . . . , ZDR 7) by "opening" the external bridge between X1997/pin 12 and X1997/pin 15; by activating the "OFF button" on the controls in the cab or in the event of switch-off conditions.Function release:
                        Approx. 3.5sec. after the terminal 15 is "on" the function can be activated by wiring with +UBat (ready for operation or terminal 15 FFR) taking the above time t into account.Caution:
                        The memory function is not effective until the button is "released" (edge change from "high" to "low"). The storage of a target speed changed with SET+/- is only possible in the relevant ZDR mode if the control function "active with storage" is parameterised and the FFR and the button is activated for at least 2 seconds.

                         A-CAN-H (plug connection X1997/pin 17)
                        CAN-high line of the body-CAN interface.

                         A-CAN-L (plug connection X1997/pin 18)
                        CAN-low line of the body-CAN interface.

                        Circuit diagram on X1997




                        9.    Description of interfaces and installation location



                        The complete interface consits of the 18-pole plug connection X1997 This plug designation is used on all circuit diagrams; the plug in the vehicle is marked with an appropriate color. Access from outside by removing the cover.

                        Plug connection

                        18-pin

                        X1997:

                        		 Color and

                        Coding:

                        beige/6

                        		 MAN item number
                        Plug housing Socket housing
                        81.25475.0046 81.25435.0927
                        Secondary lock for housing 81.25475.0065 81.25435.0913


                        Contacts (single items /strips) MAN item number
                        Blade terminal with notch 2,8´1/0,5-1 07.91202.0848 / 07.91202.0858
                        Blade terminal with notch 2,8´2,5/1,5-2,5 07.91202.0849 / 07.91202.0859
                        Spring contact with notch 2,8´1/0,5-1 07.91201.0222 / 07.91201.0221
                        Spring contact with notch 2,8´2,5/1,5-2,5 07.91201.0224 / 07.91201.0223


                        The interface "ZDR interface with the vehicle management computer for external speed control in TG" consists of the 18-pole plug connection X1996 and is included in the standard extent of the vehicle.
                        The preparation "reverse locking for refuse trucks" consists of the 6-pole plug connection X2334 or X679. This plug designation is used on all circuit diagrams the plug in the vehicle is marked in the appropriate colour. Access from outside by removing the cover.

                        Plug connection

                        6-pin

                        X1997:

                        Coding:

                        Color and

                        bue/4

                        		 MAN item number
                        Plug housing Socket housing
                        81.25435.0794 81.25435.0744
                        Secondary lock for housing 81.25435.0698 81.25435.0698


                        Contacts (individual ware / line ware) MAN item number
                        Blade terminal with notch 2,8´1/0,5-1 07.91202.0610 / 07.91202.0830
                        Blade terminal with notch 2,8´2,5/1,5-2,5 07.91202.0611 / 07.91202.0831
                        Spring contact with notch 2,8´1/0,5-1 07.91201.0222 / 07.91201.0221
                        Spring contact with notch 2,8´2,5/1,5-2,5 07.91201.0224 / 07.91201.0223


                        10.    Circuit examples

                        Circuit example for the speed triggering via an external control element with the functions "SET+" and "SET-"




                        Circuit example for the speed triggering via an external control element with the function "SET+" and "SET-"




                        Circuit example for the speed triggering via an external control element with the functions "OFF", "SET-" "MEM", and "SET+"
                        allocated according to priority




                        Circuit example for the triggering of an intermediate speed via the function "SET+" in dependence on the clutch (function release)
                        and the engagement of the power takeoff




                        Circuit example for the triggering of an intermediate speed via the function "SET+" in dependence on the brake (function release)
                        and the engagement of the power takeoff




                        Circuit example for the release of the power take-off unit with an engine-dependent power takeoff
                        in dependence on the engaged parking brake and the gearbox neutral position.




                        Circuit example for the maximum speed limitation 2 in dependence on the engaged reverse gear




                        Circuit example for the maximum speed limitation 2 in dependence on an activated step contact and the activation of the reversing lock in dependence on an activated step contact and the engaged reverse gear




                        Circuit example for the release of the power takeoff unit in dependence on the engaged parking brake and the engaged NA1




                        Circuit example for the release of the power takeoff in dependence on the engaged parking brake and the engaged NA 2




                        Circuit example for the activation of the speed limitation 1




                        Circuit example for the activation of the speed limitation 2




                        Circuit example for the activation of the speed limitation 3




                        Circuit example for the activation of the speed limitations 1, 2 and 3




                        Circuit example for the activation of the torque limitation 1




                        Circuit example for the activation of the torque limitation 2




                        Circuit example for the activation of the torque limitations 1, 2 and 3




                        Circuit example for the connection of the "KSM" and "TANK WARNING" check lamps




                        Circuit example for the connection of a body electronics with CAN interface