actros.pdf

Towing - Recovery Actros

Service

Towing – Recovery Actros Guidelines for Breakdown Services 2009 Edition

Daimler AG � Teile-Technik und Technische Information (GSP/OI) � D-70546 Stuttgart

Information and copyright

Service

If you have any questions or problems in connection with the towing or recovery of Actros vehicles, please contact:

Daimler AG Technical Field Service Tel. +49 711 / 17 - 59 762

Daimler AG � Teile-Technik und Technische Information (GSP/OI) � D-70546 Stuttgart

Information and copyright Technical details of the data and illustrations provid ed in these guidelines are subject to change without notice.

Reprinting, reproduction or translation, in whole or in part, is not permissible without the written consent of Daimler AG. All rights reserved by Daimler AG.

If you have any questions or suggestions concerning this product, please write to us at: E-mail:

[email protected]

Fax:

+49-(0) 18 05/0 12-79 78

or Address:

Daimler AG GSP/OI HPC R822, W002 D-70546 Stuttgart

Technical status: 11/2009 © 2009 Copyright Daimler AG This Manual, including all its parts, is protected under the laws of copyright. Any further processing or use requires the previous written consent of Daimler AG. This applies in particular to reproduction, distribution, alteration, translation, microfilming and storage and/or processing in electronic systems, including databases and online services.

Contents

General Safety and liability information

9

Conventions

9

Vehicle identification

10

Description and roadside assistance Quick guide Instrument panel Actros 1 (up to 12/1999) Overview Vehicle Diagnostic System/Vehicle Service System Note on display messages STOP lamp System abbreviations Display messages Indicator lamps

Instrument panel Actros 1 (as of 01/2000) Overview Driver Information System (FIS) Note on display messages STOP lamp System abbreviations Display messages Indicator lamps

Instrument panel Actros 2/3 (as of 01/2003) Overview: Actros 2 Overview: Actros 3 Onboard computer Note on display messages STOP lamp System abbreviations Display messages Indicator lamps

Warning buzzer

12

15 15 16 17 18 19 22 27

28 28 31 35 39 40 43 49

50 50 51 56 62 64 65 66 84 86

Guidelines for Breakdown Services (Subject to technical modifications) i

5

Contents Oil level in engine Actros 1 Actros 2/3

Fuel system Overview of fuel system Hand pump (location) Bleeding the fuel system

Electrical system EMERGENCY OFF switch Jump starting Batteries

Gearshift Manual gearshift system Telligent® gearshift system Telligent® automatic gearshift system and Mercedes PowerShift Teach-in process (Telligent ® gearshift/automatic gearshift system) Teach-in errors Emergency shift of manual gearshift system Actros 1: Emergency shift of Telligent ® gearshift system and Telligent® automatic gearshift system Actros 2/3: Emergency shift of Telligent ® gearshift system, Telligent® automatic gearshift system or Mercedes PowerShift

Compressed air production Versions Pressure regulating system Constant pressure system with separate four-circuit protection valve Constant pressure system with Electronic Air-Processing Unit (EAPU) Pressure table

Brake system General Telligent® brake system Frequent-stop brake Safety valve Active Brake Assist (ABA) Location of components Filling the brake system from an external source Releasing the spring-loaded parking brake

6

i Guidelines for Breakdown Services (Subject to technical modifications)

89 89 91 92 92 95 96 98 99 102 105 109 110 111 113 116 119 120 123

128 134 134 135 135 136 137 138 138 138 139 140 140 143 144 148

Contents Telligent® level control ®

Diagram of Telligent level control Raising/lowering the chassis frame Filling the air suspension system from an external source

152 152 154 156

Tilting the cab

157

Engine

163 163

Starting/stopping the engine with the cab tilted

Tow-starting Tow-starting General Preparations for tow-starting Tow-starting vehicles with manual gearshift system Tow-starting vehicles with Telligent® gearshift system Tow-starting vehicles with Telligent® automatic gearshift system and Mercedes PowerShift

165 165 165 166 166 167

Towing Quick guide

168

Towing

169 169 172 174 176 177 180 181 183 184 184 186 186 189

General Electrical circuits Air brake system Stopped engine, transmission and/or axle damage Drive and propeller shafts Towing with a tow bar Towing in raised position Raising by the wheels Raising by the front axle Raising by the front of the frame (Actros 1 only) Raising by the leaf springs (construction site vehicles only) Raising at the rear Gearshift


7

Contents

Recovery Recovery General Super-wide tires Recovering the vehicle from the rear Safety components

190 190 191 193 195

Special tools Special tools

8


196

Safety and liability information The aim of these guidelines is to provide roadside assistance and towing personnel with the instructions and information necessary in order to remove the vehicle from the scene of the breakdown or accident within 30 minutes whenever possible.

l a r e n e G

These guidelines assume that the reader understands and complies with the pertinent accident prevention regulations, any relevant professional guidelines for vehicle ownership or recovery and towing company association regulations, and the road traffic regulations of the country in question. The instructions in these guidelines, in particular particula r those pertaining to vehicle recovery, are intended exclusively for experienced recovery specialists and are left to the discretion of the user. Compensation and/or warranty claims arising from towing or recovery measures will not be accepted by Daimler AG.

$

Risk of accident

All vehicles that have been towed or recovered from a breakdown must be examined for technical condition and checked for damage at a qualified workshop which possesses all the expertise and tools required to properly perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. Pay attention to the notes in the chapter "Recovery", see page 190. 190 .

$

Risk of accident

Tampering with electronic components and their software can cause them to stop functioning. The electronic systems are networked together by interfaces. In some cases, interfering with these electronic systems can also cause malfunctions in systems that were not d irectly affected. Such malfunctions can put the operational safety of your vehicle, and thus your own personal safety, at considerable risk. Other improperly performed work or modifications to the vehicle can also jeopardize operational safety. Some safety systems operate only when the engine is running. For this reason, do not switch the engine off while driving.

Conventions

$

Warning

%

Environmental warning

!

Potential damage

+

Tip

M

Instruction

Displays

On-screen display


9

l a r e n e G

Vehicle identification Vehicle model designation 18

44

18

Permissible gross vehicle weight in in tonnes 44

Engi Engine ne outp output ut in hp (x 10) 10)

Location of vehicle model plate/vehicle identification number : Model plate (example) ; Vehicle identification number on right longitudinal frame member

Data on the vehicle model plate • • • • • • •

Vehi Vehicl cle e mode modell Head Headla lamp mp basi basic c settin setting g Smok Sm oke e ind inde ex Rear Rear axle axle rati ratio o Vehicle Vehicle ident identifi ificat cation ion number number (VIN) (VIN) Permis Permissib sible le gross gross vehicle vehicle weig weight ht Perm Permis issi sible ble axl axle e loads loads

(example)

10


Vehicle identification Key to vehicle identification number

l a r e n e G

Vehicle identification number (VIN) WDB

934.042

1 L 115548

WDB

Vehicle manufacturer 934.042

Vehicle model designation (see below) 1

Steering 1 = left-hand drive vehicles, 2 = right-hand drive vehicles L

Code letter or code number of manufacturing plant "K" up to 12.03/"L" as of 01.04 1155 115548 48

Vehi Vehicl cle e iden identi tifi fica cati tion on end end numb number er

934.04 934

Vehicle version (model designation code) 930/950 = Platform vehicle 932/952 = Dumper 933/953 = Concrete mixer 934/954 = Semitrailer tractor .04

Axle configuration 00 ... 06

4x2

07, 08

4x4

11

6 x 2 DNA (dual-tired trailing axle, Nummek)

20, 21

6x2

23

6 x 2/2 (Hendrickson leading axle, Great Britain only)

22

6 x 2/4

14, 16, 24

6x4

18, 41

6x6

30, 31, 42

8 x 4/4

32

8 x 6/4

33

8 x 8/4

8 x 8/4 8

Number of wheels or wheel pairs x8

Number of driven wheels or wheel pairs /4

Number of steered wheels

Model designations 950 – 954

Model designations 930 – 934

Actros 1 up to manufacture year 12/2002

Actr Actro os 2/3 as of manufacture year 01/2003


11

e c n a t s i s s a e d i s d a o r d n a n o i t p i r c s e D

Quick guide

Instrument panel, Actros 1 (up to 12/1999) Overview........................ Overview .................................................. .................................................... .................................................... .............................. .... Page15 Page15 Vehicle Diagnostic System (FDS)/Vehicle Service Service System System (FSS) .................... Page 16 Note on display messages ....................................................... .......................... ..................................................... ........................ Page17 Page17 STOP lamp .................................................. ........................ .................................................... .................................................... ............................ Page18 Page18 System abbreviations ........................................................ ........................... .......................................................... ............................... Page19 Page19 Display messages ..................................................... ............................ ..................................................... ....................................... ........... Page22 Page22 Electronic system malfunction displays ...................................................... ........................... ................................ ..... Page26 Page26 Indicator lamps ....................................................... ........................... ....................................................... ......................................... .............. Page27 Page27 Instrument panel Actros 1 (as of 01/2000) Overview........................ Overview .................................................. .................................................... ...................................................... .............................. .. Page28 Page28 Reservoir pressure gauge for brake circuits 1 and 2 ....................................... ............................. .......... Page 29 Gear indicator .................................................... ......................... ....................................................... .............................................. .................. Page30 Page30 Fuel level indicator................................... indicator........ ....................................................... ....................................................... ............................. Page30 Page30 Driver Information System............................ System ....................................................... ................................................... ........................ Page31 Page31 Note on display messages ....................................................... .......................... ..................................................... ........................ Page35 Page35 STOP lamp .................................................. ........................ .................................................... .................................................... ............................ Page39 Page39 System abbreviations ........................................................ ........................... .......................................................... ............................... Page40 Page40 Display messages ..................................................... ............................ ..................................................... ....................................... ........... Page43 Page43 Indicator lamps ....................................................... ........................... ....................................................... ......................................... .............. Page49 Page49 Instrument panel, Actros 2/3 (as of 01/2003) Overview: Actros 2 ...................................................... .......................... ........................................................ .................................... ........ Page50 Page50 Overview: Actros 3 ...................................................... .......................... ........................................................ .................................... ........ Page51 Page51 Reservoir pressure gauge for brake circuit 1 or 2 ............... ...................... ............... ................ .............. ...... Page52 Page 52 Gear indicator ................................................... ....................... ...................................................... ............................................... ..................... Page53 Page53 Fuel/AdBlue® level gauge ....................................................... ............................ ................................................... ........................ Page55 Page55 Onboard computer......................... computer.................................................... ..................................................... ....................................... ............. Page56 Page56 Note on display messages ....................................................... .......................... ..................................................... ........................ Page62 Page62 STOP lamp .................................................. ........................ .................................................... .................................................... ............................ Page64 Page64 System abbreviations ........................................................ ........................... .......................................................... ............................... Page65 Page65 Display messages ..................................................... .......................... ....................................................... ....................................... ........... Page66 Page66 Indicator lamps ....................................................... ........................... ....................................................... ......................................... .............. Page84 Page84 Warning buzzer Warning buzzer ....................................................... ........................... ........................................................ ......................................... ............. Page86 Page86

12


Quick guide

Oil level in engine Calling up the engine oil level on the display: Actros 1 (up to 12/1999)......... Page 89 Calling up the engine oil level on the display: Actros 1 (as of 01/2000) ......... Page 90 Calling up the engine oil level on the display: Actros 2/3 (as of 01/2003)..... Page 91 Fuel system Overview of fuel system................................................................................... Page92 Fuel tank.......................................................................................................... Page93 Hand pump location ........................................................................................ Page95 Bleeding the fuel system.................................................................................. Page96 Electrical system Overview of electrical system .......................................................................... Page98


EMERGENCY OFF switch ................................................................................. Page99 Jump starting ................................................................................................... Page102 Batteries .......................................................................................................... Page105 Gearshift Overview of gearshift ....................................................................................... Page109 Manual gearshift system.................................................................................. Page110 Telligent® gearshift system ............................................................................. Page111 Telligent® automatic gearshift system and Mercedes PowerShift ................... Page 113 Teach-in process.............................................................................................. Page116 Teach-in errors................................................................................................. Page119 Emergency shift of manual transmission (HPS) ............................................... Page120 Emergency shift of Telligent® gearshift system and Telligent® automatic gearshift system (Actros 1)............................................................. Page123 Emergency shift of Telligent® gearshift system, Telligent ® automatic gearshift system and Mercedes PowerShift (Actros 2/3) ............... Page 128 Compressed air production Versions........................................................................................................... Page134 Pressure regulating system ............................................................................. Page135 Constant pressure system with separate four-circuit protection valve ............ Page 135 Constant pressure system with Electronic Air-Processing Unit (EAPU)............ Page 136 Pressure table.................................................................................................. Page137


13


Quick guide

Brake system General ............................................................................................................ Page138 Frequent-stop brake ........................................................................................ Page139 Safety valve ..................................................................................................... Page140 Active Brake Assist .......................................................................................... Page140 Location of components .................................................................................. Page143 Filling the brake system from an external source ............................................ Page 144 Releasing the spring-loaded parking brake ...................................................... Page148 Telligent ® level control system Diagram of Telligent® level control system...................................................... Page152 General ............................................................................................................ Page153 Operating unit.................................................................................................. Page153 Raising/lowering the chassis........................................................................... Page154 Filling the air suspension system from an external source .............................. Page 156 Tilting the cab Before tilting .................................................................................................... Page157 Mechanical/hydraulic...................................................................................... Page158 Electrohydraulic ............................................................................................... Page159 Engine Starting and stopping the engine with the cab tilted ....................................... Page163

14


Instrument panel Actros 1 (up to 12/1999) Overview

1

2

3

4

5 6

13 12

7

8

9

10


11

15

14

:

STOP lamp, see page 27

G

Control buttons for Vehicle Diagnostic System (FDS)/Vehicle Service System (FSS), see page 16

;

The left-hand field of the display see page 16 shows warning indicators see page 17 and malfunction displays concerning the electronic systems see page 26.

H

Chassis display • • • •

Starting-off aid Differential lock(s) Trailing axle Power take-off(s).

=

The right-hand field of the display see page 16 shows operating information.

?

Indicator lamps, see page 27

A

Level control display

B

Coolant temperature gauge

C

Fuel level gauge

D

Engine oil pressure gauge

E

Reservoir pressure, brake circuit 1

J

Auxiliary heater timer

F


K

Tachograph

I

Gear indicator display Vehicles with Telligent® gearshift system, see page 111, or Telligent® automatic gearshift system, see page 113.

Instrument panel, Actros 1 (as of 01/2000), see page 28. Instrument panel, Actros 2 (as of 01/2003), see page 50. Instrument panel, Actros 3 (as of 06/2008), see page 51.


15


Instrument panel Actros 1 (up to 12/1999) Vehicle Diagnostic System (FDS)/Vehicle Service System (FSS) FDS

Vehicle Diagnostic System

FSS

Flexible Service System (Telligent® maintenance system)

Do not press the control buttons : until the function test is complete. The control buttons : are used e.g. to call up stored data and malfunctions from the diagnostic system.

"SYSTEM" button

The "SYSTEM" button can be used to call up operational, service and diagnostic information. This is displayed in the right-hand field of the display. With the outside temperature displayed:

M Press "SYSTEM" button once. Operating information is displayed.

M Press "SYSTEM" button twice. Service information is displayed.

M Press "SYSTEM" button three times. Diagnostic information is displayed (1st electronic system). If you continue to press the "SYSTEM" button, diagnostic information on further electronic systems is displayed.

"INFO" button Additional information in the selected electronic system is displayed.

"QUIT" button The diagnostic information disappears and the outside temperature is displayed.

Selecting language The vehicle is delivered with Service mode set to the language of the recipient country.

M Press "SYSTEM" button twice (Service mode). M Press the "INFO" button repeatedly until the language setting is shown in the display. M When the language is displayed, press and hold down the RESET button. M Then press the "QUIT" button repeatedly until the desired language is shown in the display. M Release the RESET button. The most recently d isplayed language is saved automatically. M Press the "QUIT" button to hide the display.

16


Instrument panel Actros 1 (up to 12/1999) Note on display messages Left display field : yellow/red

1

2

Automatic displays The left-hand display field automatically shows warning indicators and malfunction displays concerning the electronic systems. Each malfunction in an electronic system is indicated by a fault code, stored and assigned to a malfunction class, see page 26.

Right display field ; green/yellow Automatic displays


• Outside temperature • Operating information (e.g. fluid level in windshield washer system) • Service information Calling up displays ( see page 16 ) • • • •

Check information (e.g. engine oil pressure) Service points/service dates Stored service data Diagnostic information

Display examples Display messages, see page 22.

Display messages with code, see page 26. 0 4147: Fault code

Electronic system failure, see page 19. MR: Engine control


17


Instrument panel Actros 1 (up to 12/1999) STOP lamp M Turn vehicle key in ignition lock to drive position. The STOP lamp : goes out after max. 10 seconds or when the engine is started.

1

$

Risk of accident

If the STOP lamp does not go out or if it lights up while driving, the operational safety of the vehicle is at risk. • Stop the vehicle as soon as possible taking into account the traffic situation • Switch off the engine and apply the parking brake • Have the system checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is ab solutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. The STOP lamp : lights up:

Cause

Action

Page

Engine oil level too low.

Check engine oil level.

89

Engine oil pressure too low.

Check engine oil level.

89

Check engine oil pressure.

89

Oil level OK: Tow the vehicle away.

169

The STOP lamp : lights up and the warning "Brake system reservoir pressure" is displayed:

18

Cause

Action

Page

Reservoir pressure of brake circuit 1 or 2 below 6.8 bar.

Fill compressed air system from an external source.

144

Tow the vehicle away.

169

Reservoir pressure of brake circuit 3 below 5.5 bar.

Fill compressed air system from an external source,

144

or release spring-loaded parking brake mechanically.

150

Tow the vehicle away.

169


Instrument panel Actros 1 (up to 12/1999) System abbreviations If an electronic system fails, only the abbreviation : of the defective electronic system is displayed.

1

$

Risk of accident Drive with special care!

If an electronic system fails, this is displayed by the abbreviations below. The handling and braking behavior of the vehicle may change! Have the affected system checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

Abbreviation

Description

Action

ABS

Antilock brake system:

M Drive with special care or tow the

The wheels may lock up when braking. The lateral stability of the vehicle may change. AG (AGE)

AHE

Automatic gear selection


vehicle away, see page 153.

M Fold out the clutch pedal and shift gears manually, see page 123.

(Vehicles with Telligent® automatic gearshift system)

M Drive with special care.

Trailer recognition module:


The braking behavior of the vehicle may change. BS (EPB)

Brake control:


The braking behavior of the vehicle has changed significantly. The ABS is deactivated. The wheels may lock up when braking. The lateral stability of the vehicle may change. The brake pedal travel is longer and the brake pedal forces are higher. EAB

Electronic trailer/semitrailer brake:


The braking behavior of the vehicle may change. The wheels may lock up when braking. The lateral stability of the vehicle may change. The brake pedal travel is longer. EDW

Anti-theft alarm system

M Have the system repaired.

FFB

Radio remote control

M Lock/unlock the doors with the vehicle key.


19


Instrument panel Actros 1 (up to 12/1999) Abbreviation

Description

Action

FLA

Flame starting system (cold-starting aid):


At temperatures below –4 °C the starting characteristics change. FR (FMR)

Drive control

Activate engine limp-home mode:

M Apply parking brake and switch off engine.

M After 10 seconds, start engine. In limp-home mode the engine speed is limited to 1250 rpm. If the engine speed is not sufficient to start off or drive, tow the vehicle away, see page 169. GS (EPS)

Transmission control

M If a gearchange is no longer possible, perform an emergency shift, see page 126.

HZR

Heater control


INS

Instrument cluster:


Important information (warnings, malfunctions) can no longer be displayed.

M Tow the vehicle away if necessary,

Clutch operating system

M Fold out the clutch pedal and shift

KB


see page 169.

gears manually, see page 123.

KOM

Communications interface


KS

Clutch control



M Fold out the clutch pedal and shift

KSA

Comfort locking system


MR (PLD)

Engine control:


The accelerator pedal is inoperative and the engine speed is constantly below 1300 rpm.

M Apply parking brake and switch off


M After 10 seconds, start engine.

gears manually, see page 123.

engine.

In limp-home mode the engine speed is limited to 1250 rpm. If the engine speed is not sufficient to start off or drive, tow the vehicle away, see page 169.

20


Instrument panel Actros 1 (up to 12/1999) Abbreviation

Description

Action

NR

Level control:


The handling of the vehicle may change (e.g. chassis leans to one side, center of gravity changed). PSM

Parameterizable special module:


The power take-off is inoperative. RS (RET)

Retarder control


SIL

Seat electronics, left


SIR

Seat electronics, right


SRS

Supplemental restraint system


WS

Maintenance system


WSK

Torque converter clutch:

M Tow the vehicle away,

The handling of the vehicle may change. ZHE

Auxiliary heater


see page 169.



21


Instrument panel Actros 1 (up to 12/1999) Display messages Display messages on a yellow background Display message

Possible cause/ consequence

Possible remedy

$

M Stop the vehicle as soon as possible taking

The poly-V belt has snapped or the three-phase alternator is defective.

M Switch off engine and apply parking brake.

Risk of accident

M Check poly-V belt.

The voltage in the on-board electrical system has dropped below 22 V.

M If the poly-V belt is OK, have the electrical sys-

The handling and braking behavior of the vehicle may change.

fied workshop and have the poly-V belt replaced.

Risk of accident

$

The alternator is defective. The handling and braking behavior of the vehicle may change. A bulb or fuse in vehicle light system or brake lamp has failed.

Risk of accident

$

The reservoir pressure in the ancillary consumer circuit has dropped below 5.5 bar. The gears can no longer be shifted correctly.

Risk of accident

$

Fault in the brake system of the tractor vehicle or trailer/ semitrailer. The handling and braking behavior of the vehicle may change. The service date has been significantly exceeded.

22

into account the traffic situation.

tem checked at a qualified workshop.

M If the poly-V belt has snapped, notify a quali-

M Stop the vehicle as soon as possible taking into account the traffic situation.

M Switch off engine and apply parking brake. M Have the electrical system checked at a qualified workshop.

M Check and replace the appropriate bulb. M Check and replace the appropriate fuse. M Top up the compressed air system, fill from an external source, see page 144, or tow the vehicle away, see page 169.

M Drive with special care or tow the vehicle away, see page 169.

M Perform service.


Instrument panel Actros 1 (up to 12/1999) Display messages on a red background Display message


Possible remedy

$


The poly-V belt has snapped or the three-phase alternator is defective.


Risk of accident

into account the traffic situation.

M Check poly-V belt.

The voltage in the on-board electrical system has dropped below 22 V.

M If the poly-V belt is OK, have the electrical sys-


fied workshop and have the poly-V belt replaced.

The engine oil level has dropped about 2 l below the minimum fill level.

tem checked at a qualified workshop.

M If the poly-V belt has snapped, notify a quali-


M Switch off engine and apply parking brake. M Check engine oil level, see page 89, and top up if necessary.

The warning buzzer sounds. The STOP lamp lights up. The engine oil level has dropped below the minimum fill level. The warning buzzer sounds. The STOP lamp lights up.

M Switch off engine and apply parking brake. M Check engine for leaks. M Contact a qualified specialist workshop if there is visible oil leakage.

M Make sure that escaping oil does not contaminate the environment.

M Immediately add the oil quantity shown in the right-hand display field.

$

M Top up steering oil and drive with special care.

The oil level in the reservoir of the power steering system has dropped to the minimum fill level.

M Adjust your driving style. Reduce speed before

Risk of accident

corners in particular.

M Have the steering system checked at a qualified workshop.

If more oil is lost, there is a risk of accident because the vehicle will be difficult to steer.


23




Possible remedy

Four-axle vehicles: Steering circuit 2 has failed. The vehicle can only be steered with increased effort.

M Adjust your driving style. Reduce speed before

The coolant level has dropped about 4 l below the normal fill level.


The warning buzzer sounds.

M Top up coolant.

corners in particular.

M Have the steering system checked at a quali fied workshop. into account the traffic situation.

M Switch off engine and apply parking brake. M Have the cooling system checked for leaks at a qualified workshop.

Risk of accident

$

The reservoir pressure

M Top up the compressed air system, fill from an external source, see page 144, or tow the vehicle away, see page 169.

• in brake circuit 1 or 2 has dropped below 6.8 bar • in the spring-loaded brake and trailer brake circuit is too low or • Compressed air consumption too high while maneuvering • Compressed air system leaking. The operational safety of the vehicle is at risk.

Risk of accident

$

The service limit of the brake linings has been reached.

M Drive with special care. M Have the brake linings replaced at a qualified workshop as quickly as possible.

The braking behavior of the vehicle may change significantly.

Risk of accident

$

Brake pressure limiting. The applied brake pressures no longer correspond to the load state.

M Drive with special care. M Have the brake system checked at a qualified workshop.

The braking behavior of the vehicle is changed.

24




Possible remedy

The retarder cannot be deactivated during ABS control.


Risk of accident

$

Malfunction in brake system of trailer/semitrailer.


The handling or braking properties of the vehicle may change. Clutch overloaded: The permissible operating temperature of the clutch system has been exceeded. If the moving-off or maneuvering process is not ended within 5 seconds when the warning buzzer sounds, the clutch is closed. This can stall the engine. Observe the traffic situation.

M Leave the clutch to cool and select a lower

Display failure (vehicles with Telligent® automatic gearshift system).

M Fold out the clutch pedal and shift gears man-

Important operating information and warnings can no longer be displayed.

or


moving-off gear if necessary.

ually, see page 123.

M Drive with special care. M Tow the vehicle away, see page 169.


Risk of accident

$

Display failure. Important operating information and warnings can no longer be displayed.

M Drive with special care. or

M Tow the vehicle away, see page 169.



25


Instrument panel Actros 1 (up to 12/1999) Electronic system malfunction display :

Abbreviation

;

Fault code

Explanation of malfunction display: ABS = Abbreviation of the defective electronic system, see page 19. 0

Malfunction class 41

Fault path 47

Fault type

The coding of fault paths and fault types is accessible to workshop staff.

$

Risk of accident If the malfunction display is accompanied by a warning buzzer, this indicates that the problem poses a potential danger that can directly compromise the vehicle's operational safety.

Malfunction class

Action

0

Have the fault rectified at the next workshop service.

1

Risk of accident

$

Drive with special care! In the case of class 1 malfunctions, it may be that the handling and braking properties of the vehicle have changed. Have the malfunctions repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. 2

Risk of accident

$

Drive with special care! In the case of class 2 malfunctions, the operational safety of the vehicle is at risk. The handling and braking properties of the vehicle have changed. Have the malfunctions repaired immediately at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

26


Instrument panel Actros 1 (up to 12/1999) Indicator lamps Indicator lamp

Description High beam

Cab lock

Cargo liftgate

Frequent-stop brake


Stationary air conditioner

Parking brake

Permanent brake (retarder)

Dumper body

Acceleration skid control "ASR"

Applicable for vehicle with Telligent® automatic gearshift system: Speed too high for automatic downshift – brake! Flame starting system (cold-starting aid)


27


Instrument panel Actros 1 (as of 01/2000) Overview

:

Status indicator (yellow or red)

B

Reservoir pressure, brake circuit 2, see page 29

;

Driver Information System (FIS) display

C


• Operating information • Warnings • Display of malfunctions and failures of electronic systems Driver Information System (FIS), see page 31.

D

Multifunction display (MFD)

=


E

Fuel level gauge, see page 30

?

Reservoir pressure, brake circuit 1, see page 29

F

Coolant temperature gauge

A

Function buttons for Driver Information System (FIS), see page 31

G

Clock control buttons

H

Auxiliary heater timer

• Gear indicator, see page 30 • Trip odometer • Time.

Instrument panel, Actros 1 (up to 12/1999), see page 15. Instrument panel, Actros 2 (as of 01/2003), see page 50. Instrument panel, Actros 3 (as of 06/2008), see page 51.

28


Instrument panel Actros 1 (as of 01/2000) Reservoir pressure gauge for brake circuits 1 and 2 :


;


To ensure the operational safety of your vehicle a reservoir pressure of about 10 bar is required in the pressure circuits of the brake system. The ancillary consumer circuit is filled only after brake circuits 1 and 2 have been filled.


$

Risk of accident

Leaks in the compressed air brake system put the operational safety of the vehicle at risk. If the reservoir pressure in the compressed air brake system is too low, it is not possible to b rake the vehicle or change gear. You could cause an accident with possible injury to yourself and others. Do not set the vehicle in motion until the required reservoir pressures have been reached and the STOP lamp has gone out. If the display shows J, do not start to move the vehicle or, if moving, stop it as quickly as possible taking into account the traffic situation. In addition, the status indicator lights up red and the STOP lamp does not go out. Have the brake system checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.


29


Instrument panel Actros 1 (as of 01/2000) Gear indicator :

;

Engaged gear 1–8

1st to 8th gear

N

Transmission neutral

R

Reverse gear

Preselected gear 1–8

=

?

1st to 8th gear

Engaged splitter group

/

High-speed splitter group

0

Low-speed splitter group

Preselected splitter group

/


0


Fuel level gauge :

Fuel level gauge

M Turn vehicle key in ignition lock to drive position. M Check level on fuel level gauge : and top up if necessary.

M Switch off the engine and the auxiliary heater before filling the reservoir. Fuel reserve indicator When the content of the fuel tank has dropped to about 14%, the display shows 7. At the same time the status indicator lights up yellow.

30


Instrument panel Actros 1 (as of 01/2000) Driver Information System (FIS) The Driver Information System (FIS) informs the driver e.g. about operating information, warnings and malfunctions, while driving.

$

Risk of accident

Operating the Driver Information System (FIS) while driving can distract your attention away from what is happening on the road. You could lose control of the vehicle and cause an accident. For this reason, only operate the Driver Information System (FIS) when the vehicle is stationary with the parking brake applied.

Buttons The Driver Information System (FIS) is operated using the buttons on the instrument panel. Do not press the buttons until the automatic function test is complete.


Automatic function test

M Turn vehicle key in ignition lock to drive position. The warning buzzer sounds for about 2 seconds. At the same time all the indicator lamps light up briefly and the display shows the last menu item set.

:

RESET button

;

Function buttons

T Cancel the display and return to the next menu level up.

9 Scroll up in the active menu or select function/setting.

: Scroll down in the active menu or select function/setting.

S Select highlighted menu item or information.


31


Instrument panel Actros 1 (as of 01/2000) Driver Information System (FIS) display :

Display

;

Memory field

=


Operating information, warnings and malfunctions can be shown in the display :. At the same time the relevant segments of the status indicator ; light up yellow or red. When a malfunction/warning display is confirmed with button T, the malfunction/warning display moves to the memory field =. Malfunctions within various electronic systems can be displayed sequentially (with each display lasting about 5 seconds). If there are multiple malfunctions in an electronic system, only the event with the highest priority is displayed by the malfunction indicator.

?

Display field (example)

A

Status indicator segment

The fields ? of the display : are assigned individual segments A in the status indicator = which light up red or yellow according to the information priority rating. A warning buzzer may also sound in addition to the display message, see page 86.

32

Display

Status indicator

Confirm display with function button T, see page 31

Malfunction class, see page 36

Operating information

yellow

Display disappears

0

Operating information/warnings

yellow

Display changes to the memory field

1

Malfunction

Red

Display changes to the memory field

2


Instrument panel Actros 1 (as of 01/2000) Menus The menus each comprise a number of functions pertaining to the same subject. Certain menus can only be selected when the vehicle is stationary.

+ The number and sequence of the menus depend on the vehicle version and the vehicle equipment. Menu overview Diagnosis see page 40

Display of all diagnosable control units installed in the vehicle as well as current and stored events. If there are no events, the display shows "Unavailable". Overview of system abbreviations

Fault Info

Malfunctions in memory field.

Settings

Language


ART signal transmitter (Telligent® distance control) Display differential locks Display NR (level control) Display separation (activate and deactivate display with dashes) Service Info

Display maintenance system for general maintenance jobs according to the vehicle load.

Check Info

Axle load indicator Engine oil pressure Power take-off Other check information • Engine operating hours • Engine oil level • Engine oil top-up quantity

Equipment

Operating states of the differential locks and Telligent® level control.


33


Instrument panel Actros 1 (as of 01/2000) Selecting language When the vehicle is delivered, the language of the recipient country is set in the "Service Info" menu. Service information can be displayed in 20 languages. Operating information and further details (instructions) can only be displayed in German and English.

Displaying and changing the language setting :

RESET button

;

Function buttons

Displaying the language setting With the vehicle stationary:

M Turn vehicle key in ignition lock to drive position. M Press one of the function buttons ;. M Use 9 or : button to select the "Service Info" menu.

M Press S button. M Press : button repeatedly until the language setting is shown in the display. Changing the language setting

M With the language displayed, press and hold down the RESET button :. M Press S button repeatedly until the desired language is shown in the display. M Release RESET button :. The most recently displayed language is saved. Return to main display:

M Press T button to display the next menu level up. M Return to the main display by pressing the T button repeatedly or by holding it down (about 5 seconds). If none of the function buttons ; are pressed, the main display reappears automatically after about 30 seconds.

34


Instrument panel Actros 1 (as of 01/2000) Note on display messages Each malfunction in an electronic system (e.g. tachograph) is indi cated by a display message, and is stored and assigned to a malfunction class. Malfunctions within various electronic systems can be displayed sequentially (with each display message lasting about 5 seconds). If there are multiple malfunctions in an electronic system, only the display message with the highest priority is shown. In the event of failure or malfunction of an electronic system, the display shows either the system abbreviation with a display message or the event code.

Display message with system abbreviation :

System abbreviation of electronic system, see page 40


TCO: Tachograph

;

Function restrictions (cause of malfunction) Text message: "Stop Vehicle – Load Tachograph Disk"

=

Location of malfunction:

6 Tractor vehicle 1 Trailer/semitrailer ?

Further information is available.

M Press S button on instrument panel. A



35


Instrument panel Actros 1 (as of 01/2000) Display with event code (example) :

System abbreviation of electronic system, see page 40 "BS": Brake control

;

Status indicator (red)

=

2

80

00

2

Event code Malfunction class The malfunction class is either "0", "1" or "2", see page 36.

80

Fault path 00

?

Fault type

Further information is available.

M Press S button on instrument panel. Malfunctions within various electronic systems can be displayed sequentially (with each display message lasting about 5 seconds). If there are multiple malfunctions in an electronic system, only the display message with the highest priority is shown.

Risk of accident

$

If a display message appears and the warning buzzer sounds at the same time, the operational safety of the vehicle is at risk. Have the malfunctions repaired immediately at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is ab solutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

36


Instrument panel Actros 1 (as of 01/2000) Malfunction class 0

:

Status indicator yellow

;

Malfunction class "0"

Have class "0" malfunctions repaired at a qualified specialist workshop during the next service.


Malfunction class 1

:

Status indicator yellow

;


The malfunction display reappears after the engine is restarted. In the memory field, see page 32, display messages for various electronic systems can be shown sequentially (with each display lasting about 5 seconds). If there are multiple malfunctions in an electronic system, only the display message with the highest priority is shown.

$

Risk of accident

In the case of class "1" malfunctions, it may be that the handling and braking properties of the vehicle have changed. Adjust your driving style accordingly and drive with special care. Follow the instructions and observe the additional information in the Driver Information System (FIS). Have the cause checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.


37


Instrument panel Actros 1 (as of 01/2000) Malfunction class 2

:

Status indicator red

;


The malfunction display reappears after the engine is restarted. In the memory field, see page 32, display messages for various electronic systems can be shown sequentially (with each display lasting about 5 seconds). If there are multiple malfunctions in an electronic system, only the display message with the highest priority is shown.

Risk of accident

$

Drive with special care! In the case of class "2" malfunctions, the operational safety of the vehicle is at risk. The handling and braking properties of the vehicle may change. If it is possible to drive on: Adjust your driving style accordingly and drive with special care. Continuing to drive may result in damage to the vehicle and is against the law. If it is not possible to drive on: • Stop the vehicle immediately in a safe place taking into account the traffic situation • Follow the instructions and observe the additional information in the Driver Information System (FIS) • Have the affected system checked and repaired immediately at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is ab solutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

38


Instrument panel Actros 1 (as of 01/2000) STOP lamp

Risk of accident

$

If the STOP lamp does not go out or if it lights up while driving, the operational safety of the vehicle is at risk. • Stop the vehicle as soon as possible taking into account the traffic situation. • Apply the parking brake and switch off the engine. • Have the affected system checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work

1


Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.


39


Instrument panel Actros 1 (as of 01/2000) System abbreviations

$

Risk of accident

If an electronic system fails, this is displayed by the abbreviations below. The handling and braking behavior of the vehicle may change! Have the affected system checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is ab solutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

Abbreviation

Description

Action

ABS

Antilock brake system:

M Drive with special care or tow the

The wheels may lock up when braking. The lateral stability of the vehicle may change. AG


vehicle away, see page 169.


M Drive with special care. ART

Autonomous intelligent cruise control:


Inoperative BS

Brake control: The braking behavior of the vehicle has changed significantly. ABS is deactivated.


The wheels may lock up when braking. The lateral stability of the vehicle may change. Brake pedal travel longer, brake pedal forces increased. EAB

Electronic trailer/semitrailer brake: The braking behavior of the vehicle may change.


The wheels may lock up when braking. The lateral stability of the vehicle may change. Brake pedal travel longer. EDW



FFB

Radio remote control


FLA

Flame starting system (cold-starting aid):


If temperatures are below –4 °C, the starting characteristics change.

40


Instrument panel Actros 1 (as of 01/2000) Abbreviation

Description

Action

FR

Drive control



M After 10 seconds, start engine. In limp-home mode the engine speed is limited to 1250 rpm.

M If the engine speed is not sufficient to start off or drive, tow the vehicle away, see page 169. GS

Transmission control

M If a gearchange is no longer possible, perform an emergency shift, see page 126.

HPS

Manual gearshift system (HPS)

M Perform emergency shift,


see page 120. HZR

Heater control


INS

Instrument cluster:


Important information (warnings, malfunctions) can no longer be displayed.

or


KOM



KS

Clutch control


Vehicles with Telligent® automatic gearshift system


KSA



MR

Engine control:


Accelerator pedal inoperative and constant engine speed below 1300 rpm.


M After 10 seconds, start engine. In limp-home mode the engine speed is limited to 1250 rpm.

M If the engine speed is not sufficient to start off or drive, tow the vehicle away, see page 169. NR

Level control:


The handling of the vehicle may change (e.g. chassis leans to one side, center of gravity changed). PSM

Parameterizable special module:


Power take-off inoperative. RS

Retarder control



41


42

Instrument panel Actros 1 (as of 01/2000) Abbreviation

Description

Action

SIL

Seat electronics, left


SIR

Seat electronics, right


SPA

Lane Assistant


SRS



TCO

Tachograph


WS

Maintenance system


WSK

Torque converter clutch:

M Tow the vehicle away,

The handling of the vehicle may change.

see page 169.

ZHE

Auxiliary heater


ZV

Central locking



Instrument panel Actros 1 (as of 01/2000) Display messages Display message with yellow status indicator Display message

Possible cause/consequence

Risk of accident

Possible remedy

$

The poly-V belt has snapped or the threephase alternator is defective. The voltage in the on-board electrical system has dropped below 22 V. The handling and braking behavior of t he vehicle may change.



M Check poly-V belt. M If the poly-V belt is OK, have the electrical system checked at a qualified workshop.

M If the poly-V belt has snapped,


notify a qualified workshop and have the poly-V belt replaced.

$

M Stop the vehicle as soon as

The handling and braking behavior of t he vehicle may change.

M Switch off engine and apply

Risk of accident The alternator is defective.

possible taking into account the traffic situation. parking brake.

M Have the electrical system checked at a qualified workshop. • No monitoring of the trailer/ semitrailer. • When switching on the lights: Bulb or fuse for standing lamps, low beam lamps, taillamps, license plate illumination or rear fog lamp is defective. • When braking: Brake lamp is defective. • When signaling: Turn signal lamp is defective. • After the instrument panel function check: Fuse for brake lamps is defective.

M Check and replace the appro-

The oil level of the automatic engine oil refill system has dropped to about 3.5 l.

M Top up.

priate fuse.

M Check and replace the appropriate bulb.


43


Instrument panel Actros 1 (as of 01/2000) Display message with yellow status indicator Display message


Possible remedy

Engine oil level has dropped to minimum fill level.

M Top up.

Coolant level has dropped about 2 l below the normal fill level.

M Top up.

Coolant temperature is too high. The engine output is automatically reduced.

M Demand less power from the engine.

M Make sure that the air supply to the radiator is not obstructed. Fuel level has dropped to about 14% of maximum fill level.

M Refuel.

The fluid level in the reservoir of the windshield washer/headlamp cleaning system has dropped to about 1 l.

M Top up.

Risk of accident

$

The reservoir pressure for ancillary consumers has dropped below 5.5 bar. The clutch can no longer be fully disengaged and reliable gearchanges are no longer possible.

Risk of accident

$

Fault in brake system of tractor unit or trailer/semitrailer.

M Top up the compressed air system, fill from an external source, see page 144, or tow the vehicle away, see page 169.


The handling and braking behavior of the vehicle may change. The parking brake was not applied before engaging the PTO.

M Apply parking brake.

Vehicles with Telligent® automatic gearshift system: The parking brake was not applied before switching off the engine.

44


Instrument panel Actros 1 (as of 01/2000) Display message with yellow status indicator Display message


Risk of accident

Possible remedy

$

Fault in Telligent® automatic gearshift system. The warning buzzer sounds.


M Drive with special care. M Wait until the warning buzzer

You cannot start the engine.

stops.

Immobilizer is activated.

M Turn the vehicle key in the ignition lock all the way back.

M Repeat the start attempt after about 2 seconds.


Display message with red status indicator Display message


Risk of accident

Possible remedy

$

The poly-V belt has snapped or the threephase alternator is defective. The voltage in the on-board electrical system has dropped below 22 V. The handling and braking behavior of the vehicle may change.




M If the poly-V belt has snapped, notify a qualified workshop and have the poly-V belt replaced. The engine oil pressure is too low. The warning buzzer sounds. The STOP lamp lights up.

M Stop the vehicle as soon as

The operational safety of the engine is at risk.

M Switch off engine and apply

possible taking into account the traffic situation. parking brake.

M Check engine oil level, see page 90, and top up.


45


Instrument panel Actros 1 (as of 01/2000) Display message with red status indicator Display message


Possible remedy

Engine oil level has dropped about 2 l below minimum fill level. The warning buzzer sounds.


The STOP lamp lights up.

Risk of accident

$

M Top up steering oil and drive with special care.

The oil level in the reservoir of the power steering system has dropped to the minimum fill level. If more oil is lost, there is a risk of accident because the vehicle will be difficult to steer. The STOP lamp lights up. Four-axle vehicles: Steering circuit 2 has failed. The vehicle can only be steered with increased effort.

M Adjust your driving style. Reduce speed before corners in particular.

M Have the steering system checked at a qualified workshop.

Coolant level has dropped about 4 l below the normal fill level. The warning buzzer sounds.



M Top up coolant. M Have the cooling system checked for leaks at a qualified workshop.

Risk of accident

$

M Top up the compressed air system or fill from an external source, see page 144.

Reservoir pressure • in brake circuit 1 or 2 has dropped below 6.8 bar • in the spring-loaded brake and trailer brake circuit is too low or

or


• Compressed air consumption too high while maneuvering • Compressed air system leaking. The operational safety of the vehicle is at risk.

46




Risk of accident

Possible remedy

$

The service limit of the brake linings has been reached. The braking behavior of the vehicle may change significantly.

Risk of accident

$

Malfunction in brake system of trailer/ semitrailer. The handling or braking properties of the vehicle may change.

Risk of accident

$

Brake pressure limiting. The applied brake pressures no longer correspond to the load state.

M Drive with special care. M Have the brake linings replaced at a qualified workshop as quickly as possible.




M Have the brake system checked at a qualified workshop.

The braking behavior of the vehicle is changed.

M Drive with special care. The retarder cannot be deactivated during ABS control or when depressing the accelerator pedal. Vehicles with Telligent® automatic gearshift system: Clutch overloaded: The permissible operating temperature of the clutch system has been exceeded. If the moving-off or maneuvering process is not ended within 5 seconds when the warning buzzer sounds, the clutch may overheat.

M Leave the clutch to cool and select a lower moving-off gear if necessary.


47


48



Risk of accident

Possible remedy

$

Display failure. Important operating information and warnings can no longer be displayed.

M Drive with special care. M Tow the vehicle away, see page 169.

The handling and braking behavior of the vehicle may change. The service date has been significantly exceeded.

M Perform service. M Have the service work performed at a qualified workshop.


Instrument panel Actros 1 (as of 01/2000) Indicator lamps Indicator lamp

Description Dumper body

Acceleration skid control "ASR" and Telligent ® stability control "SR"

Applicable for vehicle with Telligent® automatic gearshift system: Speed too high for automatic downshift – brake! Torque converter clutch


Flame starting system (cold-starting aid)

Cargo liftgate

Frequent-stop brake

Stationary air conditioner

Parking brake applied.

Permanent brake

Steering lock of hydraulically steered trailing axle.

Cab lock

Lane Assistant


49


Instrument panel Actros 2/3 (as of 01/2003) Overview: Actros 2

:

Speedometer with display for trip mileage and total mileage

B

Reservoir pressure gauge for brake circuit 1 or 2, see page 52

C

Brake circuit 2 indicator lamp, see page 52

;


D


=


E

Button for instrument illumination brighter

?

Display, see page 57

F

Button for instrument illumination darker

A

Tachometer with

G

RESET button

• Ecometer • Clock • Outside temperature indicator.

H

Button for confirming display messages

I

Button for resetting trip mileage to "0"

J


K

AdBlue® level gauge, see page 55


50


Instrument panel Actros 2/3 (as of 01/2003) Overview: Actros 3

:

Speedometer with display for trip mileage and total mileage

B

Reservoir pressure gauge for brake circuit 1 or 2, see page 52

C


;


D


=


E

Button for instrument illumination brighter

?

Display, see page 57

F

Button for instrument illumination darker

A

Tachometer with

G

RESET button

• Ecometer • Clock • Outside temperature indicator.

H

Button for confirming display messages

I

Button for resetting trip mileage to "0"

J


K

AdBlue® level gauge, see page 55




51


Instrument panel Actros 2/3 (as of 01/2003) Reservoir pressure gauge for brake circuits 1 and 2 :

Brake circuit 1 indicator lamp

;

Brake circuit 2 indicator lamp

=

Reservoir pressure gauge for brake circuit 1 or 2

To ensure the operational safety of your vehicle a reservoir pressure of about 10 bar is required in the pressure circuits of the brake system, or 11 bar in vehicles with Electronic Air-Processing Unit (EAPU), see page 136. The ancillary consumer circuit is filled only after brake circuits 1 and 2 have been filled.

Reservoir pressure (example on Actros 2)

M Turn vehicle key in ignition lock to drive position. The brake circuit with the lowest reservoir pressure is displayed automatically by the appropriate indicator lamp : or ;. The gauge = shows the reservoir pressure in this brake circuit.

+ You can check the reservoir pressure of both brake circuits in the Check Info menu under Reservoir pressure.

Risk of accident

$

Leaks in the compressed air brake system put the operational safety of the vehicle at risk. If the reservoir pressure in the compressed air brake system is too low, it is not possible to b rake the vehicle or change gear. You could cause an accident with possible injury to yourself and others. Do not set the vehicle in motion until the required reservoir pressures have been reached and the STOP lamp has gone out. If the display shows J, do not start to move the vehicle or, if moving, stop it as quickly as possible taking into account the traffic situation. In addition, the status indicator lights up red and the STOP lamp does not go out. Have the brake system checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is ab solutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

52


Instrument panel Actros 2/3 (as of 01/2003) Gear indicator Telligent ® automatic gearshift system and Mercedes PowerShift (16-speed transmission) The display shows the following information: • The engaged engaged gear and and the engage engaged d splitter splitter group group : • The transm transmiss ission ion mode mode ; • The active active operat operating ing mode mode =.

:

; =

/


0


1–8

1st to 8th gear

N


R1, R2

Reverse gears 1 and 2 (Mercedes PowerShift)

R

Reverse gear (Telligent® automatic gearshift system)

E

EcoRoll mode

P

Power mode

A

Automatic mode

M

Manual mode


Gear indicator in display

Mercedes PowerShift (12-speed transmission) Depending on the transmission version, the display shows the following information: • The The enga engage ged d gea gearr : • The transm transmiss ission ion mode mode ; • The active active operat operating ing mode mode =.

:

1–12

1st to 12th gear

N/E

Transmission neutral, highspeed splitter group

/ N/E

; =

0

Transmission neutral, lowspeed splitter group

R1–R4

1st to 4th reverse gear

E

EcoRoll mode

P

Power mode

A

Automatic mode

M

Manual mode

Gear indicator in display


53


54

Instrument panel Actros 2/3 (as of 01/2003) Telligent ® gearshift system (16-speed transmission) The display shows information on the engaged gear and the engaged splitter group : as well as on the recommended or preselected gear with the corresponding splitter group ;.

/


0


1–8

1st to 8th gear

N


R

Reverse gear Gear indicator in display


Instrument panel Actros 2/3 (as of 01/2003) Fuel/AdBlue® level gauge :

AdBlue® level gauge

;

Fuel level gauge

M Turn vehicle key in ignition lock to drive position. M Check level on fuel/AdBlue ® level gauge and top up if necessary.

M Switch off the engine and the auxiliary heater before filling the reservoir. Fuel reserve indicator When the content of the fuel tank has dropped to about 14%, the display shows 7. At the same time the status indicator lights up yellow.

Fuel/AdBlue® level gauge (example on Actros 2)


+ The fuel supply and range can be called up in the Trip computer menu.

AdBlue® level gauge The AdBlue® level gauge : only shows the approximate AdBlue® level. The AdBlue® level is indicated by 4 blue segments.

1 segment

AdBlue® level between reserve and tank 1/4 full

2 segments

AdBlue® level between tank 1/4 and 1/2 full

3 segments

AdBlue® level between tank 1/2 and 3/4 full

4 segments

AdBlue® level between tank 3/4 full and tank full

+ The current AdBlue ® level, in liters, is only displayed in the Check Info menu.

! If the AdBlue® reservoir is empty or there is a malfunction in the BlueTec ® exhaust aftertreatment system, the indicator lamp ; lights up. In this case the vehicle must be refueled with AdBlue® or the fault must be rectified immediately.

+ The current AdBlue® level, in liters, is only displayed in the onboard computer menu under Actros Info/Check Info, see page 60. 60 .


55


Instrument panel Actros 2/3 (as of 01/2003) Onboard computer The onboard computer informs the driver e.g. about fuel consumption, journey time, events, operating states, service dates, malfunctions, fault causes and remedial action, while driving. The onboard computer is operated using the buttons on the multifunction steering wheel and the buttons on the instrument panel.

Operation Risk of accident

$

Operating the onboard computer while driving can distract your attention away from what is happening on the road. You could lose control of the vehicle and cause an accident. For this reason, only operate the onboard computer when the vehicle is stationary with the parking brake applied.

Onboard computer (example on Actros 3)

:

Display

B

;

Á Reset button:

: Accept call/redial

Reset trip data

9 End call or direct access to telephone menu

Reset trip counter

=

T Confirm display messages

?

? RESET button:

Scroll up/down in main menu

Confirm service work performed.

Confirm display message

Change operating fluid data in menu Settings/ submenu Operating fluids.

Return to main menu

A

WX Adjust volume on audio device (radio and telephone). Select submenus in the menus Language, Settings and Diagnosis. Actros 2: Change values in the menus New SMS, Auxiliary heater, Alarm clock and Settings. Call up data in the menu Diagnosis for service personnel.

56

Telephone:

C

VU

The most recently selected settings are saved automatically.

D

Scroll in submenu (select function):

& Forward Back º Back Actros 3: Change values in the menus New SMS, Auxiliary heater, Alarm clock and Settings. Call up data in the menu Diagnosis for service personnel.


Instrument panel Actros 2/3 (as of 01/2003) Display fields :

Basic display with speedometer and text information (display messages, instructions etc.)

;

Symbols or system abbreviations, e.g. for the ABS function check, display messages, service indicators, malfunctions and status indicator (white, yellow and red)

=

Menu display or status indicator (white, yellow or red)

?

Operation indicator for level control (vehicles with air suspension)

A

Gear indicator (transmissions with Telligent® gearshift system, Telligent ® automatic gearshift system or Mercedes PowerShift)

B

Reminder field (stored malfunctions or received SMS messages)

C

Operation indicator for differential locks

D

Operation indicator for cruise control, speed limiter, Telligent® distance control, Active Brake Assist


The fields of the display change automatically depending on the display type and priority rating (e.g. operation indicators, display messages, menus). Display fields may also be linked together. If certain settings can be made in a menu, this is ind icated in the display by the symbol º. Settings are made using the buttons W and X on the multifunction steering wheel. Status indicator Individual segments of the status indicator light up white, yellow or red to distinguish display messages according to their priority rating. Display messages with yellow or red status indicator, (see page 66).


57


Instrument panel Actros 2/3 (as of 01/2003) Menus The various main menus each comprise a number of functions pertaining to the same subject. Certain menus can only be selected when the vehicle is stationary.

+ The number and sequence of the menus depend on the vehicle model and the vehicle equipment.

Menu overview Main menu

Submenu

Actros Info

Speed Date Clock

Check Info

AdBlue® level gauge

(see page 60)

Coolant temperature Brake system reservoir pressure Oil level in engine Operating hours Axle loads Cargo monitoring Trailer ID number

Trip computer (trip data)

After start After reset Diesel fuel tank Driver 1

Maintenance

Time-based servicing Brakes A1-A4 Air filter Air drier Engine X General Transmission Rear axle Front axle Retarder Coolant Transfer case

Event Info (see page 61)

58

Malfunctions


Instrument panel Actros 2/3 (as of 01/2003) Main menu

Submenu

Auxiliary heater

Temperature Set temperature Heating duration Set memory

Alarm clock

Wakeup mode Wakeup time

Language Settings

Configuration Cargo monitoring Clock Units


Operating fluids GS back-up mode (transmission emergency mode) (see page 128) Diagnosis (service personnel) Navigation (Audio APS 30) Audio (radio)

Base functions in radio\cassette or CD player mode.

SMS (FleetBoard®) Telephone


59


Instrument panel Actros 2/3 (as of 01/2003) Check Info menu M Turn vehicle key in ignition lock to drive position. M Press buttons on multifunction steering wheel. Menu: Actros Info/Check Info

Description

1. VU

Main menu – Check Info

2. &*

9

The AdBlue® level is 90 l.

AdBlue tank 90 l

The display shows the current AdBlue® level in a bar graph and in liters.

(example text)

9

The AdBlue® supply is down to the reserve level.

AdBlue reserve

9

The AdBlue® supply is exhausted.

AdBlue empty

9 AdBlue tank --- l

2. &*

Coolant temperature (°C)

The onboard computer cannot determine the AdBlue® level. The engine coolant temperature

(0...+120 °C) 2. &*

Reservoir pressure (\/ ^)

Reservoir pressure in brake circuit 1/brake circuit 2

--.- bar / --.- bar

2. &*

60

Oil level

Engine oil level O.K. or top-up quantity or overfilled

O.K. or -.- l / >max.

• Oil level O.K. = Engine oil level OK • Oil level -.- l = Top-up quantity in liters • Oil level >max. = Engine oil level too high (overfilled)


Instrument panel Actros 2/3 (as of 01/2003) Menu – Event Info M Turn vehicle key in ignition lock to drive position. M Press buttons on multifunction steering wheel and on instrument panel. Menu: Actros Info/Event Info

Description

1. VU

Main menu – Event Info

2. &*

INS

Stored malfunctions: System abbreviation, see page 65, or symbol, see page 62, malfunction location, function restriction, instruction.


Speed logging disrupted – Immediate service required

(example text) 3. T or

Press T button (confirm display message).

VU


61


Instrument panel Actros 2/3 (as of 01/2003) Note on display messages Display messages are operating information, fault messages or warnings that appear automatically in the display. The status indicator lights up white, yellow or red depending on the priority rating. In addition to the display message, an indicator lamp on the instrument panel may light up or the warning buzzer may sound. Display messages can be canceled and called up at a later time in the Event Info menu. If an indicator lamp lights up with the display message, it will not go out again even when the display message is confirmed. If several events have occurred, the display messages are shown alternately. In the case of significant malfunctions, the display message is backed up by the warning buzzer and the STOP lamp.

Display message with system abbreviation :

Status indicator (white, yellow or red)

;

System abbreviation

=

Location of malfunction:

6 Tractor vehicle 1 Trailer/semitrailer ?

Function restrictions

A

Instruction

B

Reminder field for stored malfunctions

Display message with symbol

62

:

Status indicator (white, yellow or red)

;

Symbol

B

Reminder field


Instrument panel Actros 2/3 (as of 01/2003) Confirm display message M Press button T, V or U. The display message disappears and can be called up in the Event Info menu, see page 61.

+ If the cause of the fault is not rectified when the engine is restarted, the display message reappears.

Display message with yellow status indicator

$

Risk of accident

The operational safety of the vehicle may be compromised if there is a display message with yellow status indicator. Adjust your driving style accordingly and drive with special care. Follow the instructions and observe the additional information in the display.


Have the cause checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

Display message with red status indicator

$

Risk of accident

The operational safety of the vehicle is compromised if there i s a display message with red status indicator. The handling and braking properties of the vehicle may change. If it is possible to drive on: Adjust your driving style accordingly and drive with special care. Continuing to drive may result in damage to the vehicle and is against the law. If it is not possible to drive on: • Stop the vehicle immediately in a safe place taking into account the traffic situation • Follow the instructions and observe the additional information in the display • Have the affected system checked and repaired immediately at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It i s absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.


63


Instrument panel Actros 2/3 (as of 01/2003) Reminder field In the reminder field the onboard computer displays appropriate symbols or system abbreviations as reminders about display messages that have been confirmed. If several events are present that must be displayed by law, they are displayed alternately.

Symbols in reminder field

, Collective symbol for malfunctions BS

Malfunction in Telligent® brake system

* New SMS message SRS

Malfunction in supplemental restraint system (airbag, emergency tensioning retractor)

TCO

Malfunction in tachograph

The events stored in the reminder field can be viewed in the Event Info menu, see page 61.

Status indicator Segments of the status indicator light up yellow or red to distinguish display messages according to their priority rating. The status indicator lights up yellow for particular operating states (e.g. differential lock switched on) and malfunctions of low priority (e.g. when a bulb is defective). The status indicator lights up red for malfunctions of high priority, e.g. when the alternator is defective.

STOP lamp :

STOP lamp

Risk of accident

$

If the STOP lamp does not go out or if it lights up while driving, the operational safety of the vehicle is at risk. • Stop the vehicle as soon as possible taking into account the traffic situation • Switch off the engine and apply the parking brake • Have the affected system checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is ab solutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

64


Instrument panel Actros 2/3 (as of 01/2003) System abbreviations Abbreviation

System

Abbreviation

System

ABA

Active Brake Assist

KSA


ABS

Antilock brake system

MR

Telligent® engine control

AG


MSF

Modular switch panel

APU

Air-processing unit

NR

Telligent® level control

ART

Telligent® distance control

PSM

Parameterizable special module

BS

Telligent® brake system

RAD

Radio/navigation system

BTS

Battery disconnect switch

RS

Retarder control

EAB

Electronic trailer brake

SPA

Lane Assistant

EDW


SRS


FLA

Flame starting system (cold-starting aid)

TCO

Tachograph

FM

Front module

TEL

Telephone, hands-free system

FR

Drive control

TMB

Passenger door module

GM

Base module

TMF

Driver door module

GS

Telligent® transmission control

TP

Telematics platform

HM

Rear module

WR

Telligent® roll control

HPS

Manual gearshift system (HPS)

WS

Telligent® maintenance system

HZR

Heater control/air conditioning

WSK

Torque converter clutch

INS

Instrument cluster

ZDS

Central data memory

KB

Clutch operating system

ZHE

Auxiliary heater

KOM


ZL

Telligent® trailing axle

KS

Clutch control



65


Instrument panel Actros 2/3 (as of 01/2003) Display messages Display message with white status indicator Display message


VP

Active Brake Assist is switched on.

Active Brake Assist

Possible remedy

Switched on

VP

Active Brake Assist

Active Brake Assist is switched off.

M Switch on Active Brake Assist.

Active Brake Assist may be faulty, the antilock brake system (ABS) may be switched off or the brake system of the vehicle may have a malfunction.

M Pay particular attention to the traffic

Switched off

VP

Active Brake Assist Cannot be activated

Risk of accident

situation.

M Brake the vehicle with the service brake.

M Have the Active Brake Assist system checked at a qualified workshop.

$

You will not receive any distance warnings if Active Brake Assist is not switched on. The vehicle will not be braked automatically in critical situations. Pay particular attention to the traffic situation. Emergency braking complete!

Active Brake Assist had automatically initiated emergency braking (emergency stop). Emergency braking is complete.

M Remove the vehicle from the danger area as soon as possible taking into account the traffic situation.

M Switch off the engine and secure the vehicle with the parking brake to prevent it from rolling.

M Check the condition of the vehicle and check that the cargo is properly secured.

66


Instrument panel Actros 2/3 (as of 01/2003) Display message with yellow status indicator Display message


Possible remedy

9P 9P

The fuel supply is exhausted.

M Fill the fuel tank.

Top up AdBlue

The AdBlue® supply is down to the reserve level.

M Fill AdBlue® tank.

9P

Top up diesel

The fuel supply is down to the reserve level.


9P

Refuel diesel, refueling AdBlue recommended

The fuel supply is down to the reserve level.


Top up diesel and AdBlue

The fuel and AdBlue ® supplies are down to the reserve level.


The fluid level in the reservoir of the windshield washer/ headlamp cleaning system has dropped to about 1 l.

M Fill the reservoir of the windshield

The left brake lamp on the trailer/semitrailer is defective.

M Check and replace the appropriate

• When switching on the lights: Bulb or fuse for standing lamps, low beam lamps, taillamps, license plate illumination or rear fog lamp is defective. • When braking: Brake lamp is defective. • When signaling: Turn signal lamp is defective. • After the instrument panel function check: Fuse for brake lamps is defective.

M Check and replace the appropriate

The engine oil level is too low.

M Add the oil quantity shown in the dis-

9P ¨P

4N

Left brake lamp defective (example)

4P

0P

7.5l (example)

M To avoid the need for another refueling stop, fill the AdBlue® tank at the same time.


M Fill AdBlue® tank. washer/headlamp cleaning system.

bulb (see operator's manual of trailer/semitrailer).

fuse.

M Check and replace the appropriate bulb.

+ Monitoring by the onboard computer can be deactivated in some cases. If this is the case, a visual inspection by the driver is necessary!

play. If it is not possible to top up the displayed oil quantity, the vehicle can still be driven driving depending on operating conditions. It is possible to drive approximately another 20006000 km or until the status indicator lights up red.


67




Possible remedy

¿P

A service date is due shortly.

M Schedule the service for the due date.

A service date is due.

M Have the service work performed at a

Air filter 01.04.04 3100 km (example)

¿P

Air filter service due

qualified workshop.

(example)

,P

M Top up coolant.

The coolant level has dropped.

M If the coolant level drops again, have the cooling system checked for leaks at a qualified workshop.

+P

Malfunction of the air drier.

M Have the air drier checked at a qualified workshop.

:P

Risk of accident

$

The reservoir pressure in the ancillary consumer circuit has dropped below 5.5 bar. The gears can no longer be shifted correctly.


M Apply parking brake. M Run the engine until the display message disappears and a sufficient reservoir pressure is obtained.

M If the fault occurs frequently, have the compressed air system repaired at a qualified workshop.

:P

BP

Vehicles with Telligent® automatic gearshift system: The reservoir pressure in the ancillary consumer circuit is too low. The Telligent® automatic gearshift system is inoperative.

M Stop the vehicle, taking into account

Malfunction in the electronic drive control.


the traffic situation.

M Apply parking brake. M Switch off the engine and restart.

M Stop the vehicle, taking into account the traffic situation.

The accelerator pedal is inoperative and the engine runs in limp-home mode.

M Switch off engine and apply park-

The engine output is reduced.

M Wait about 10 seconds and restart

ing brake. the engine. If the engine is still running in limphome mode: Have the fault rectified at a qualified specialist workshop.

68




Possible remedy

BP

The engine runs at a constant speed of 1300 rpm. Engine limp-home mode is activated.

M Visit a qualified specialist workshop.

/P


M Repeat the start attempt after about

The starter batteries are discharged.

10 seconds. Note that excessively long start attempts drain the batteries.

M Jump start the engine from another vehicle.

/P

Immobilizer activated.

You cannot start the engine. You have attempted to start the engine 5 times with an invalid vehicle key. The immobilizer is activated.

M Use a valid vehicle key or the spare


key.

+ Any additional starting attempt with an invalid vehicle key increases the waiting time by 1 more minute. Mercedes-Benz recommends that you always carry a spare key in an easily accessible location for emergencies.

FP

The temperature at one wheel brake of the tractor vehicle is too high. The wheel brake may overheat.

M Drive with special care. M Shift to a lower gear and use the permanent brake as much as possible to brake the vehicle.


FN

Wheel brake overloaded

The temperature at one wheel brake on the trailer/ semitrailer is too high. The wheel brake may overheat.

M Drive with special care. M Shift to a lower gear and use the permanent brake as much as possible to brake the vehicle.


KN

LN

The cargo temperature set on the cargo monitor in the trailer/semitrailer has been exceeded or undershot.

M Have the cargo monitoring system

The cargo pressure set on the cargo monitor in the trailer/ semitrailer has been exceeded or undershot.


checked at a qualified workshop.



69




Possible remedy

MN

The cargo fluid level set on the cargo monitor in the trailer/ semitrailer has been exceeded or undershot.


The ramp starting-off aid has been switched on.

M Observe the distance indicator in the

The distance sensor is dirty.

M Clean the lens of the distance sensor

SN UP

display.

in the front bumper with clean water and a soft cloth. Do not use dry, rough or hard cloths and do not rub or scratch the lens.

UP

VP

VP

70

Clean distance sensor


Distance control: Restrictions possible

The Telligent® distance control is malfunctioning.

M Have the Telligent® distance control

Active Brake Assist unavailable

Active Brake Assist is unavailable.


The vehicle will not be braked automatically in critical situations. You must brake the vehicle with the service brake.

M Brake the vehicle with the service

Active Brake Assist is malfunctioning.


The vehicle will not be braked automatically in critical situations. You must brake the vehicle with the service brake.

M Brake the vehicle with the service

Active Brake Assist: Function restricted


situation. brake.


situation. brake.




GP


Possible remedy

Up to 05/2005:

Risk of accident

Clutch: Failure. Use GS back-up mode

Vehicles with Telligent® gearshift system/automatic gearshift system/Mercedes PowerShift: Insufficient reservoir pressure in ancillary consumer circuit. The transmission can no longer shift.

As of 06/2005 Clutch: Failure. Service required

$


M Apply parking brake. M Run the engine until there is sufficient reservoir pressure in the ancillary consumer circuit again. The display message about the ancillary consumer reservoir pressure disappears.

M Switch off engine.


M Wait about 10 seconds and restart the engine.

M If the display still shows the display message Clutch failure, perform the "minor teach-in process", see page 116.

M If the "minor teach-in process" is unsuccessful, perform the "major teachin process", see page 118.

M If the "major teach-in process" is unsuccessful, activate GS back-up mode, see page 128.

GP

Gearshift: Failure. Perform major teach-in process

Risk of accident

$

Vehicles with Telligent® gearshift system/automatic gearshift system/Mercedes PowerShift: The transmission can no longer shift.


M Apply parking brake. M Switch off engine and apply parking brake.

M Perform the "major teach-in process", see page 118.

GP

Gearshift: Failure. Use GS back-up mode

Risk of accident

$

Vehicles with Telligent® gearshift system/automatic gearshift system/Mercedes PowerShift: Electronic system of transmission control is malfunctioning.

M Activate GS back-up mode, see page 128.

M Tow the vehicle away, see page 169. M Have the gearshift system checked at a qualified workshop.

The transmission can no longer shift.


71



GP

Parameterization error. Perform major teach-in process


Risk of accident

Possible remedy

$

Vehicles with Telligent® gearshift system/automatic gearshift system/Mercedes PowerShift: The transmission can no longer shift.



M Perform the "major teach-in process", see page 118.

0P

Torque converter mode/ no accelerator shutoff

No CAN link to the FR. Information on idle and kickdown speeds is missing.

M Have the torque converter clutch

0P

Torque converter activated

Torque converter mode is activated.

-

0P

Torque converter: Permanently activated

There is a malfunction at the solenoid valve of the torque converter clutch.


Torque converter: Restrictions possible

-


Retarder lever!

The function of the retarder is restricted.

0P

0P

checked and repaired at a qualified workshop.



The retarder is inoperative.

M Have the torque converter clutch checked and repaired at a qualified workshop.

The retarder operates with no function restrictions.

0P 0P

Retarder!

Valve!

The retarder cannot be shut off.




The retarder brake responds with a delay.

checked and repaired at a qualified workshop. checked and repaired at a qualified workshop.

The torque converter is permanently active. The retarder operates with no function restrictions.

0P

72

Temperature sensor!






Possible remedy

0P



Electronics!


0P

Network!




The torque converter is permanently active. Torque converter mode/no accelerator shutoff: No CAN link to the FR. Information on idle and kickdown speeds is missing.



0P

Retarder: Restrictions possible


The retarder lever is inoperative. There is a malfunction of the temperature sensor.

0P

3P

Temperature of torque converter clutch too high

The vehicle was driven for too long in torque converter mode.


Shift to a lower gear in order to increase the engine speed to over 1200 rpm. When the torque converter clutch is closed, the indicator lamp X goes out.

$

M Stop the vehicle as soon as possible

The voltage in the on-board electrical system has dropped below 22 V. The poly-V belt has snapped or the alternator is defective.

M Switch off engine and apply parking

Risk of accident


taking into account the traffic situation. brake.

M If the poly-V belt is OK, have the electrical system checked at a qualified workshop.

M If the poly-V belt has snapped, notify a qualified workshop and have the poly-V belt replaced.


73



3P


Risk of accident

Possible remedy

$

The alternator is defective. The handling and braking behavior of the vehicle may change.



M Have the electrical system checked at a qualified workshop.

CN

The braking behavior may change.

Risk of accident

$



The handling or braking properties of the vehicle may change. Up to 05/ 2005:

Risk of accident

$

Parking brake is not applied.

MP

M Apply the parking brake when parking the vehicle.

The vehicle was parked with a gear engaged and the parking brake released. When the engine is switched off, the transmission automatically shifts to neutral. This can cause the parked vehicle to roll away. This may cause injury to yourself and others.

Up to 05/ 2005:

Vehicles with parameterizable special module (PSM): Parking brake is not applied.

MP

M Apply the parking brake before switching on the PTO.

The parking brake was not applied before switching on the PTO. This can cause the parked vehicle to roll away. This may cause injury to yourself and others. Up to 05/ 2005:

¿P

Air filter Immediate service (example)

74

A service date has been significantly exceeded.

M Have the service work performed at a qualified workshop.

Risk of damage to the vehicle and its major assemblies.


Instrument panel Actros 2/3 (as of 01/2003) Display message with yellow status indicator Display message Up to 05/ 2005:

NP


Brake A1

Risk of accident

Immediate service

Due service work has not been performed.

(example)

Possible remedy

$

M Have the brake linings replaced at a qualified workshop.

The service limit of the brake linings or the brake disks has been exceeded. The handling and braking behavior of the vehicle may change.

6P

The braking behavior may change. Visit a workshop at the first opportunity.

Risk of accident

$

Malfunction in the brake system of the vehicle.

M Have the brake system checked at a


qualified workshop.

The handling or braking properties of the vehicle may change.


75


Instrument panel Actros 2/3 (as of 01/2003) Display message with yellow status indicator and warning buzzer Display message


Possible remedy

0P ;

Vehicles with Telligent® automatic gearshift system: The permissible operating temperature of the clutch has been exceeded. There is a risk of clutch damage.

M Shift to a lower gear to maneuver the

The coolant temperature is too high. The engine output is automatically reduced.

M Reduce speed and shift down to a

DP ;

Coolant temperature too high

vehicle or to move off.

M Finish the moving-off or maneuvering process as quickly as possible.

lower gear if necessary.

M Make sure that the air supply to the radiator is not obstructed.

/P ;

CODE


M Wait until the warning buzzer stops.

The immobilizer is activated.


M Repeat the start attempt after about 2 seconds. You cannot start the engine. You have attempted to start the engine with an invalid vehicle key. The immobilizer is activate.

S;

76

The ramp distance is less than 50 cm.

M Use a valid vehicle key or the spare key.

+ After 5 invalid start attempts the display shows Immobilizer activated.

M Observe the distance indicator in the display.


Instrument panel Actros 2/3 (as of 01/2003) Display message with red status indicator Display message As of 06/ 2005


Engage parking brake

MP

Risk of accident

Possible remedy

$

Parking brake is not applied.

M Apply the parking brake when parking the vehicle.

Vehicles with Telligent® automatic gearshift system and Mercedes PowerShift: The vehicle was parked with a gear engaged and the parking brake released. When the engine is switched off, the transmission automatically shifts to neutral. This can cause the parked vehicle to roll away. This may cause injury to yourself and others.

As of 06/ 2005

Engage parking brake

MP

Risk of accident

$

Vehicles with parameterizable special module (PSM): Parking brake is not applied.


M Apply the parking brake before switching on the PTO.

The parking brake was not applied before switching on the PTO. This can cause the parked vehicle to roll away. This may cause injury to yourself and others. As of 06/ 2005

¿P As of 06/ 2005

NP

Air filter Immediate service (example) Brake A1 Immediate service (example)

A service date has been significantly exceeded. Risk of damage to the vehicle and its major assemblies.

Risk of accident

$

Due service work has not been performed.

M Have the service work performed at a qualified workshop.

M Have the brake linings replaced at a qualified workshop.

The service limit of the brake linings or the brake disks is past maximum. The handling and braking behavior of the vehicle may change.


77


Instrument panel Actros 2/3 (as of 01/2003) Display message with red status indicator Display message


Possible remedy

$P

The alternator or the poly-V belt is defective.




M If the poly-V belt has snapped, notify a qualified workshop and have the polyV belt replaced.

+P

Power reduced

There may be a fault in the exhaust aftertreatment system. The indicator lamp ; flashes. The engine output is reduced.

M Shift the transmission manually. M Confirm the display message. If the display message appears only temporarily, no action is required.

M Have the fault rectified at a qualified workshop.

®

Vehicles with Telligent automatic gearshift system/ Mercedes PowerShift: The transmission switches to manual mode.

+

P

Service required

There is a fault in the exhaust aftertreatment system. The permissible emission levels are exceeded.

M Have the fault rectified at a qualified workshop. If the fault is not rectified, the indicator lamp ; flashes and the engine power is automatically reduced the next time the vehicle comes to a standstill. If the exhaust aftertreatment system operates properly over the course of several journeys, the full engine power is available again and the indicator lamp ; goes out.

+

P

Service required

The indicator lamp ; flashes.

M Have the fault rectified at a qualified workshop.

The NOx sensor is defective.

78




Possible remedy

9P




M Confirm the display message.

Power reduced Top up AdBlue

M Shift the transmission manually.

The engine output is reduced. Vehicles with Telligent® automatic gearshift system/ Mercedes PowerShift: The transmission switches to manual mode.

9P

AdBlue empty


When the AdBlue® supply is topped up, the display message does not reappear the next time the engine is started. The indicator lamp ; goes out. The full engine power is available again.



If the AdBlue® supply is not topped up, the indicator lamp ; flashes and the engine power is reduced the next time the vehicle comes to a standstill. When the AdBlue® supply is topped up, the display message does not reappear the next time the engine is started. The indicator lamp ; goes out. The full engine power is available again.

CN

The braking behavior is changed

Risk of accident

$


M Continue driving with special care. M Have the brake system checked at a qualified workshop.

The handling or braking properties of the vehicle have changed. Up to 05/ 2005:

1P

The braking behavior is changed

Risk of accident

$

The full braking power is not available.

As of 06/ 2005

M Shift to a low gear and use the permanent brake as much as possible to brake the vehicle.


CN 6P

M Continue driving with special care.

Brake force increased

Risk of accident

Pedal travel lengthened Immediate service required

$

Malfunction in the brake system of the vehicle.

M Continue driving with special care. M Have the brake system checked at a qualified workshop.

The handling or braking properties of the vehicle have changed.


79



NP

Brake linings fully worn


Risk of accident

Possible remedy

$

M Continue driving with special care. M Have the brake linings on the trailer/

Due service work has not been performed. The service limit of the brake linings or the brake disks on the trailer/semitrailer is past maximum.

semitrailer replaced at a qualified workshop as quickly as possible.


MN

The handling and braking behavior may change.

Risk of accident

$

M Continue driving with special care. M Avoid heavy braking, except in emer-

The trailer/semitrailer is braked automatically.

gency situations, so that the wheels of the trailer/semitrailer do not lock up.

M Have the trailer/semitrailer checked at a qualified workshop.

7P

Malfunction in the retarder control. The retarder is not deactivated during ABS control or when depressing the accelerator pedal.

8N

.P

IP

80

Malfunction in trailer ABS

Risk of accident

$

M Continue driving with special care. M Have the retarder control checked at a qualified workshop.

M Continue driving with special care.

The antilock brake system (ABS) in the trailer/ semitrailer is not functioning. There is a risk of excessive braking at the trailer/ semitrailer.

M Avoid heavy braking, except in emer-

The oil level in the reservoir of the power steering system has dropped to the minimum fill level.

M Have the steering system checked at

Four-axle vehicles: Steering circuit 2 has failed.

M Adjust your driving style. Reduce

The vehicle can only be steered with increased effort.

M Have the steering system checked at

gency situations, so that the wheels of the trailer/semitrailer do not lock up.

M Have the trailer/semitrailer ABS checked at a qualified workshop.

a qualified workshop.

speed before corners in particular. a qualified workshop.




Possible remedy

/P

The engine oil level is too high. This can cause the engine oil pressure to drop. The operational safety of the engine is at risk.

M Have at least 2 liters of oil extracted

The vehicle was driven for too long in torque converter mode.

Shift to a lower gear in order to increase the engine speed to over 1200 rpm. When the torque converter clutch is closed, the indicator lamp X goes out.

0P

Converter temp.

at a qualified workshop. If too much oil is added, there is a risk of damage to the engine or catalytic converter (vehicles with BlueTec ® exhaust aftertreatment).



81


Instrument panel Actros 2/3 (as of 01/2003) Display message with red status indicator and warning buzzer Display message

·;


Risk of accident

Possible remedy

$

During an automatic distance warning it is absolutely essential to brake the vehicle with the service brake when:

M Pay particular attention to the traffic situation.

M Brake the vehicle with the service brake.

• The display shows · with red status indicator • A double warning tone sounds • A constant warning buzzer sounds

5P ;

,P ;

Risk of accident

$

The CAN bus, the data transfer system to the instrument panel, has failed. The display can no longer show important information concerning the operational safety of the vehicle. Coolant level has dropped 2 l below the normal fill level. The operational safety of the engine is at risk.



M Notify a qualified specialist workshop.



M Top up coolant. M Have the cooling system checked for leaks at a qualified workshop.

82


Instrument panel Actros 2/3 (as of 01/2003) Display message with red status indicator and STOP lamp Display message


OP

Risk of accident

¤

The reservoir pressure

Possible remedy

$

• in brake circuit 1 or 2 has dropped below 6.8 bar • in the spring-loaded brake and trailer brake circuit is too low


M Apply parking brake. M Run the engine to top up the compressed air supply.

M Do not continue to drive until the STOP lamp has gone out.

The operational safety of the vehicle is at risk.

M Have the compressed air brake system checked for leaks at a qualified workshop.


Display message with red status indicator, warning buzzer and STOP lamp Display message


Possible remedy

.P

The engine oil pressure is too low.

M Stop the vehicle as soon as possible

;¤

The operational safety of the engine is at risk.

taking into account the traffic situation.



M Notify a qualified specialist workshop.

0P

12.5 l

;¤

(example)

The engine oil level is significantly too low. The operational safety of the engine is at risk.



M Check engine for leaks. Contact a qualified specialist workshop if there is visible oil leakage. Make sure that escaping oil does not contaminate the environment.

M Add the oil quantity shown in the display immediately.


83


84

Instrument panel Actros 2/3 (as of 01/2003) Indicator lamps Indicator lamp

Function

G I H J

Turn signal indicator, tractor vehicle, left

M K V ! x

Low beam

¤

STOP lamp

H

Cab lock

d

Acceleration skid control (ASR)/Telligent® stability control (SR)

W ; % Ô X Õ Z G D Ò

Permanent brake; Telligent® automatic gearshift system

Turn signal indicator, trailer/semitrailer, left Turn signal indicator, trailer/semitrailer, right Turn signal indicator, tractor vehicle, right

High beam Permanent brake Parking brake Frequent-stop brake

Engine diagnosis Flame starting system (cold-starting aid) Lane Assistant (SPA) Torque converter clutch (WSK) Telligent® trailing axle Hill holder Dumper body Cargo liftgate Stationary air conditioner


Instrument panel Actros 2/3 (as of 01/2003) Engine diagnosis indicator lamp

$

Risk of accident

Always have service work performed at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. In particular, it is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. There is a risk of accident and injury if these jobs are not performed properly.

Problem


Possible remedy

The indicator lamp ; lights up briefly.

During the Instrument display check, the indicator lamp ; lights up briefly and goes out again if there is no malfunction.

-


The AdBlue® supply is exhausted or there is a malfunction.

M Fill AdBlue® tank immedi-

At the same time the display shows a display message with red status indicator:

The engine output may be reduced.


ately.

9P The indicator lamp ; lights up.

The indicator lamp ; lights up. Emissions-relevant malfunction or fault in the BlueTec® exhaust aftertreatment system. This malfunction or fault could result in damage or degradation of the exhaust aftertreatment system.

M Have the BlueTec ® exhaust aftertreatment system checked as quickly as possible at a qualified specialist workshop.

The engine output may be reduced.


85


Warning buzzer

Warning buzzer The warning buzzer sounds in addition to the operating information in the display. Warning buzzer function (test circuit)

M Turn vehicle key in ignition lock to drive position. The warning buzzer sounds for about 2 seconds. Overview of warning buzzer in addition to display message or indicator lamp Warning buzzer ; sounds when

Display

Action

Engine oil level too low.

0

M Check engine oil level.

The STOP lamp lights up at the same time.

¤

Actros 1 (up to 12/1999), see page 89. Actros 1 (as of 01/2000), see page 90.

The operational safety of the vehicle is at risk. Engine damage is possible.

Actros 2/3 (as of 01/2003), see page 91.

Engine oil pressure too low.

.

The STOP lamp lights up at the same time.

¤


The operational safety of the vehicle is at risk. Engine damage is possible. Malfunctions in certain electronic systems.

Malfunction displays and display messages: Actros 1 (up to 12/1999), see page 22.


Actros 1 (as of 01/2000), see page 43. Actros 2/3 (as of 01/2003), see page 66.

Maximum permissible engine speed exceeded.

M If the warning buzzer sounds when shifting


M If the warning buzzer sounds when tow-starting,

Coolant level too low or coolant temperature too high. The operational safety of the vehicle is at risk. Engine damage is possible.

86

down, select a higher gear. reduce the towing speed or select a higher moving-off gear.

,

M Check cooling system for leaks. M Top up coolant or tow the vehicle away if necessary, see page 169.


Warning buzzer

Warning buzzer ; sounds when

Display

Action

Permissible coolant temperature exceeded.

Up to 05/ 2005:

M Demand less power from the engine.

D As of 06/ 2005

M Reduce speed and shift down to a lower gear if necessary.

M Make sure that the air supply to the radiator is not obstructed.

D

P M Fold out clutch pedal, see page 123.

Actros 1: Telligent® automatic gearshift system when the clutch pedal must be folded out. If the service brake is released, the vehicle key in the ignition lock is turned all the way back or removed and the frequent-stop brake is activated.

x


M Apply parking brake. M Press bottom of frequent-stop brake switch. The indicator lamp x in the instrument panel goes out.

Risk of accident

$

The parking brake must be applied in order to switch off the engine. Otherwise the vehicle can roll away unintentionally. Malfunction in Active Brake Assist (ABA)

·

M Press top of Active Brake Assist OFF switch. The indicator lamp in the Active Brake Assist OFF switch lights up red. Active Brake Assist is switched off.

+ When the engine is restarted, the Active Brake Assist is switched back on automatically. Vehicle stationary and hill holder activated if no pedal actuation (clutch or brake pedal) occurs.

Z

M Operate service brake; apply parking brake if necessary.

+ The hill holder is merely an aid intended to provide assistance when moving off.

Activated immobilizer.

/

M Wait until the warning buzzer stops.

P


M Repeat start attempt with a valid vehicle key or spare key after about 2 seconds.

+ Any additional starting attempt with an invalid vehicle key increases the waiting time by 1 more minute. After 5 invalid start attempts the display shows Immobilizer activated.


87


Warning buzzer

Warning buzzer ; sounds when

Display

Action

If reverse gear is engaged and there is an obstacle closer than 50 cm from the vehicle rear.

S

M Observe the distance indicator in the display. M Increase the distance to the obstacle. + If necessary, a second person should assist with the maneuvering.

Telligent® automatic gearshift system when the clutch is overloaded.

Up to 05/ 2005:

M Leave the clutch to cool and select a lower moving-off gear if necessary.

0 As of 06/ 2005

0P Display failure.

5


5P


+ The display can no longer show important information concerning the operational safety of the vehicle. Damage of failure in the CAN bus, the data transfer system to the instrument panel.

+ The display can no longer show important information concerning the operational safety of the vehicle. If the lights are switched on and the vehicle key is removed.

M Switch off lights.

The seat belt on the driver seat is not buckled.

M Buckle up seat belt.

If reverse gear is engaged. Telligent® adaptive cruise control with risk of a collision.

M Reduce speed and watch the traffic.

Active Brake Assist distance warnings.

88


Oil level in engine

Actros 1: Calling up the engine oil level/pressure on the display Up to 12/1999 Checking engine oil level To check the engine oil level the vehicle must be parked on level ground. The engine oil level can be called up on the display with the engine off or with it running.

M Apply parking brake. M Turn vehicle key in ignition lock to drive position. M Wait for the function test to finish. M Press "SYSTEM" button once.


The display shows the operating information :.

M Press "INFO" button once. The display shows the operating information, either the top-up quantity, e.g. 4.5 l ;, or engine oil level O.K. =. Add the oil quantity shown in the display. The oil filler opening is behind the maintenance flap. Do not overfill the engine! Checking engine oil pressure

M Start engine. M Press "SYSTEM" button once or twice.

1

The display shows the operating hours :.

M Press "INFO" button twice.

2

The display shows the current engine oil pressure ?. Idle speed about 550 rpm = min. 0.5 bar. Rated rpms about 1800 rpm = min. 2.5 bar

3

4


89


Oil level in engine

As of 01/2000 Checking engine oil level To check the engine oil level the vehicle must be parked on level ground. The engine oil level can be called up on the display with the engine off or with it running.

M Apply parking brake. M Turn vehicle key in ignition lock to drive position. M If the outside temperature is displayed after the function test, press any function button :. M Use 9 or : button to select the Check Info menu.

M Press S button. M Use 9 or : button to select the Other menu line.

M Press S button. The display shows engine oil level O.K. or the topup quantity in liters. Add the oil quantity shown in the display. The oil filler opening is behind the maintenance flap. Do not overfill the engine! Checking engine oil pressure

M Start engine. M Press any function button :. M Use 9 or : button to select the Check Info menu.

M Press S button. M Use 9 or : button to select the Oil pressure menu.

M Press S button. The display shows the current engine oil pressure. Idle speed about 550 rpm = min. 0.5 bar Rated rpms about 1800 rpm = min. 2.5 bar

90


1

Oil level in engine

Actros 2/3: Calling up the engine oil level in the display To check the engine oil level the vehicle must be parked on level ground and the engine must have been switched off for at least one minute. In order to receive as accurate a reading as possible, wait about 10 minutes if the engine is cold or about 1 minute if it is warm. If the engine oil level is called up earlier, the display will not show the correct quantity. If the engine oil level is called up while driving, the display always shows the engine oil level measured the last time the engine was off.

M Switch off engine and apply parking brake. M Turn vehicle key in ignition lock to drive position. M Wait about 1 minute. M Press the VU buttons on the multifunction steering wheel repeatedly until the Check Info is displayed. M Press the &* buttons repeatedly until the display shows Oil level.


If the display shows • Oil level O.K. = Engine oil level OK • Oil level -.- l = Top-up quantity in liters • Oil level >max. = Engine oil level too high (overfilled)

! Only top up the engine oil when the display shows 0 with a yellow status indicator.


91


92

Fuel system

Overview of fuel system (example)

:

AdBlue® tank

A

Fuel filter

;

Fuel tank with fuel pump unit

B

High pressure pumps

=

Hand pump (example) Location of hand pump, see page 95.

C

Fuel pump

?

Injection nozzles

D

Engine control unit


Fuel system

Fuel tank Main fuel tank The main fuel tank is usually located on the righthand side of the vehicle frame. The main fuel tank can be recognized by the fuel pump unit.


Additional fuel tank Additional fuel tanks may be mounted on the left or right side of the vehicle frame. They are identifiable by a cap with vent line or by a fuel pump unit with no electrical connection.


93


Fuel system

Combination tank Filler neck

:

Diesel fuel

;

Hydraulic fluid 2

The combination tank consists of two separate chambers for diesel fuel and hydraulic fluid.

+

1

It is possible for the hydraulic tank to be installed separately.

AdBlue® tank The AdBlue® tank is on the right-hand side of the vehicle frame and is identifiable by its blue cap. AdBlue® is a noncombustible, nontoxic, colorless, odorless and water-soluble liquid.

! Only use AdBlue® that conforms with DIN 70 070. Special additives are not permissible. If AdBlue® comes into contact with painted or aluminum surfaces during refueling, rinse off the affected areas immediately with plenty of water. (example)

Risk of injury

$

Please make sure that: • AdBlue® does not come into contact with your skin, eyes or clothing • AdBlue® is kept away from children If you or others have come into contact with AdBlue ®: • In the event of eye contact, flush out the eyes immediately with plenty of clean water and seek medical attention if necessary • Wash affected areas of the skin with plenty of clean water • If AdBlue® has been swallowed, rinse out the mouth immediately with plenty of clean water and drink plenty of water. Seek medical attention if necessary.

94


Fuel system

Hand pump (location) Vehicles are fitted with either the hand pump : or the fuel prefilter with heated water separator ;. A hand pump is integrated into the top section of the fuel prefilter housing ;.

+ The installation location varies depending on version.

: or ?

Hand pump

; or =

Fuel prefilter with heated water separator



95


Fuel system

Bleeding the fuel system System without fuel prefilter M Check whether the filter in the sightglass : of the hand pump is heavily clogged.

M If the filter is heavily clogged: Unscrew sightglass : using a wrench (size 19 mm) and clean filter.

M Start engine and run for about 1 minute. The fuel system bleeds itself automatically. If the engine stops or fails to start after about 1 minute:

M Bleed the fuel system with the hand pump. ! Bleeding the fuel system by running the starter for a long time is not permissible. Long starting procedures can damage the starter. Bleeding the fuel system with the hand pump

M Remove cap of fuel tank. M Release handle of hand pump ; by turning counterclockwise.

2

M Operate hand pump (about 100 times) until a noticeable resistance can be felt.

M Press handle of hand pump ; all the way down and tighten by turning clockwise.

M Close cap of fuel tank. 1

96


Fuel system

System with fuel prefilter M Before bleeding, check whether water has settled in the sightglass :.

3

If water has settled in the sightglass :, drain water from fuel system.

4

M Close knurled screw ? on fuel prefilter. M Place a container under drain screw ;. M Slacken drain screw ;. M Operate hand pump = and collect the water/ 1

fuel mixture. 2

M Tighten drain screw ;. M Open knurled screw ? on fuel prefilter.


M Remove cap of fuel tank. M Slacken bleed screw A. M Check that the knurled screw ? is at "FUEL ON". M Place receptacle underneath. M Operate hand pump =. M Bleed until the fuel emerges free of bubbles. If no fuel emerges, refuel main fuel tank with diesel and repeat the procedure.

M Tighten bleed screw A. M If the system is completely empty, operate hand pump = about 200 times (to bleed the fuel system).

M Fit and tighten cap of fuel tank. M Start engine. %

Environmental warning Dispose of the water/fuel mixture properly without contaminating the environment.


97


98

Electrical system

Overview of electrical system

:

Batteries arranged one above the other

A

EMERGENCY OFF switch on the instrument panel, see page 100

;

Batteries arranged side by side

B

EMERGENCY OFF switch on right wheel well, see page 101

=

Batteries in rear of vehicle in semitrailer tractors with integral rear end

C

RESET switch (export vehicles for France), see page 101

?

Batteries behind the cab on heavy-duty tractor units (SLT)

D

Jump-start connection point (semitrailer tractors with integral rear end), see page 103


Electrical system

EMERGENCY OFF switch Vehicles used to transport hazardous goods may be equipped with 2 EMERGENCY OFF switches depending on their ADR classification. The switches are used to interrupt the power supply in an emergency. This prevents short circuits with sparks which may ignite a fire or an explosion.

$

Risk of accident

Press the EMERGENCY OFF switch only in the event of danger and only when the vehicle is stationary; never while driving. The EMERGENCY OFF switch kills the engine automatically, i.e. the power steering is inoperative as well. The vehicle can only be steered with increased effort. In addition the power supply to all important electrical consumers (e.g. vehicle lights, antilock device etc.) is interrupted. The operational safety of the vehicle is compromised and there is a greater risk of accident.


If the power supply is interrupted with the EMERGENCY OFF switch while the anti-theft alarm system is active, the anti-theft alarm system triggers an alarm.

Deactivating anti-theft alarm system (EDW) d

Actros 1

e

Actros 2/3

:

Switch

;

Indicator lamp

M Unlock driver door with vehicle key. or

M Unlock vehicle with radio remote control. or

M Press switch : in switch unit on dashboard. The vehicle key in the ignition lock must be turned all the way back or removed.

Canceling the alarm M Press % button on radio remote control. or

M Unlock driver door (hold vehicle key in unlock position) or

M Press top (Actros 2/3) or bottom (Actros 1) of switch :.


99


Electrical system

EMERGENCY OFF switch on the instrument panel

EMERGENCY OFF switch, Actros 1

EMERGENCY OFF switch, Actros 2

Interrupting the power supply

M Open cover. M Pull out switch pin. All consumers are disconnected from the battery with the exception of the tachograph. Restoring the power supply


M Press cover of EMERGENCY OFF switch down until it clicks into place.

EMERGENCY OFF switch, Actros 2/3

M Turn vehicle key in ignition lock to drive position. The power supply to all consumers is restored.

100


Electrical system

EMERGENCY OFF switch behind the cab on the right wheel well Interrupting the power supply

M Open cover. M Swing switch lever ; up. All consumers are disconnected from the battery with the exception of the tachograph. Restoring the power supply


M Press cover down until it clicks into place. M Turn vehicle key in ignition lock to drive position.


The power supply to all consumers is restored. Vehicles with RESET switch (export vehicles for France) The RESET switch : is on the battery supporting frame. If an EMERGENCY OFF switch has been operated, press the RESET switch : before restarting the vehicle:

M Switch off both EMERGENCY OFF switches.

1

M Open cover of RESET switch. M Swing switch lever to the left. M Press cover all the way to the right. The RESET switch : is automatically restored to the basic position and the vehicle is operational again.


101


Electrical system

Jump starting When the vehicle batteries are flat, another vehicle can be used to jump start the engine.

Risk of injury

$

Charging batteries produces explosive oxyhydrogen gas. For this reason, always ensure good ventilation when working on batteries. Do not use fire or open flames near batteries, and do not smoke. Avoid producing sparks (e.g. when disconnecting the batteries). Sparks can ignite the oxyhydrogen gas and cause the batteries to explode. You and others could be seriously injured.

Risk of injury

$

While jump starting, there is a risk of caustic burns due to gases escaping from the batteries. Do not lean over the batteries when jump starting.

! Do not use a quick charger for jump starting. Discharged batteries may freeze at temperatures of –10 °C. In this case do not start the engine. Let the battery thaw out first. Only jump start from vehicles with 24 V system. Use jumper cables that are protected against reverse polarity and have a cross section of about 35-50 mm² and insulated terminal clips. Before jump starting with a mobile charging station (battery with power supply unit), pull the mains plug. Overvoltages can damage electronic components in the vehicle.

! Before jump starting, the condition of the batteries must be checked. The vehicle must not be jump started when the batteries • are visibly damaged • are frozen • or the fluid level has dropped below "Min." (see "Min./Max." mark on battery housing). Replace the batteries. Discharged batteries may freeze at temperatures of –10 °C. In this case do not start the engine. Let the battery thaw out first. Do not use a quick charger for jump starting. Only jump start from vehicles with 24 V system. Use jumper cables that have a cross section of about 35–50 mm² and insulated terminal clips. Before jump starting with a mobile charging station (batteries with power supply unit), pull the mains plug. Overvoltages can damage electronic components in the vehicle.

102


Electrical system

Semitrailer tractors with batteries integrated in the vehicle rear do not need to be uncoupled for jump starting. They are equipped with a jump-start socket on the left side of the vehicle. Location of batteries and jump-start socket, see page 98.

Jump-start socket (semitrailer tractors with integral rear end)

:

Positive terminal cover (red)

;

Negative terminal cover (black)

M Before jump starting, disconnect all mobile communications systems, such as telephone, twoway radio, fax etc., from the electrical system.

M Make sure that the vehicles do not touch. M Turn the vehicle key in the ignition lock all the


way back.

M In vehicles used to transport hazardous goods, check that the EMERGENCY OFF switches are switched off and that the RESET switch (export vehicles for France) has been operated.

M Switch off all electrical consumers. M Vehicles with jump-start connection point: Remove covers on positive terminal : and negative terminal ;. M Vehicles with batteries mounted at the side on the chassis frame: Remove battery cover. M Connect first the positive terminals and then the negative terminals with the jumper cables. ! Do not connect the ground cable to the vehicle frame. This can cause damage to the engine or transmission components. Vehicle supplying power:

M Run the engine at a high speed. Vehicle receiving power:

M Turn vehicle key in ignition lock to dri ve position. On vehicles with cold-starting aid, make sure that the ind icator lamp % goes out. M Start engine and run at idle speed. ! When removing the jumper cables, the engine of the vehicle receiving power should only be running at idle speed. This prevents voltage spikes. If the batteries are deeply discharged, wait a few minutes before removing the jumper cables.

M Remove jumper cables first from the negative terminals and then from the positive terminals. M Have the batteries checked at a qualified specialist workshop, e.g. a Mercedes-Benz service center.


103


104

Electrical system

Risk of accident

$

When towing or recovering a vehicle with a gear engaged, the engine can start unintentionally and the vehicle could drive off out of control. You could cause an accident with possible serious or fatal i njury to yourself or others. Before towing or recovering, make sure that the ignition in the vehicle is switched off and that no gear is engaged. Disconnect the battery if: • the ignition cannot be switched off • the batteries are deeply discharged • the cab is not accessible, e.g. due to an accident


Electrical system

Batteries

Risk of explosion/injury

A

$

Risk of explosion Charging batteries produces explosive oxyhydrogen gas. Batteries should only be charged in wellventilated rooms.

D

Risk of explosion Avoid producing sparks! Do not use fire or open flames near batteries, and do not smoke.

B

Battery acid is corrosive. Wear acid-proof protective gloves! Splashes of acid on the skin or clothing should be neutralized immediately with soapy water or an acid neutralizer, and then rinsed with water.

E

Wear eye protection. When mixing water and acid the fluid can splash into your eyes. If acid splashes in the eyes, flush it out immediately with clean water and seek medical attention without delay!

C

Keep children away. Children are incapable of appreciating the dangers of handling batteries and acid.

F

When handling batteries, always comply with the safety information, precautions and procedures contained in the operating instructions.


%

Environmental warning

K

Batteries contain pollutants. Old batteries must not be discarded with household refuse.

I

Dispose of batteries in an environmentally acceptable way. Hand in batteries to a specialist workshop, a Mercedes-Benz service center or a recycling station for used batteries. Full batteries must be transported and stored upright. Secure batteries to prevent them from tipping over while transporting. Battery acid can escape from the blow holes of the stop plugs and contaminate the environment.


105


Electrical system

Disconnecting and connecting batteries Location of batteries, see page 98. On vehicles with batteries at the rear (semitrailer tractors with batteries integrated at the rear and integral rear end), the batteries are only accessible after uncoupling the semitrailer.

Risk of injury

There is a risk of short circuit if the positive terminal of the connected battery comes into contact wi th vehicle parts. This can cause the highly volatile gas mixture to ignite. You and others could be seriously injured. • • • •

Never place any metal objects or tools on the batteries When disconnecting the batteries, always disconnect first the negative and then the positive terminal When connecting the batteries, always connect first the positive and then the negative terminal Never disconnect or connect the battery terminals while the engine is running.

Disconnecting batteries

! Vehicles with BlueTec® exhaust aftertreatment: Wait at least 5 minutes after switching off the engine before disconnecting the battery. This period is necessary to ensure proper operation of the exhaust aftertreatment system after restarting.

M Turn the vehicle key in the ignition lock all the way back and remove.

M Switch off all electrical consumers. M Remove battery cover. M Disconnect negative terminal :. M Disconnect positive terminal ;. Connecting batteries

M Turn the vehicle key in the ignition lock all the way back and remove. M Switch off all electrical consumers. M Connect positive terminal ;. Do not mix up the terminals!

M Connect negative terminal :. After a power interruption, perform the following work:

M Set clock. M Deactivate anti-theft system on audio device (radio) (see manufacturer's operating instructions).

106

$


Electrical system

Battery tray Vehicles with low bodies may be fitted with a battery tray. This can be used to check the batteries.

! Disconnect the battery terminals before pulling out the battery tray! Pulling out battery tray

M Disconnect batteries. M Unscrew bolts : using wrench (size 13 mm). M Pull out battery tray.

1


1

Removing/installing batteries (vehicles with batteries arranged one above the other)

$

Risk of injury

Batteries are very heavy. When removing or installing a battery, it may fall and cause injury to yourself and others. For this reason be especially careful when removing the battery and get a second person to assist.

M Observe the safety information, see page 105. Removing batteries

+ To remove the battery, unscrew only the marked bolts on the retaining frame on the battery carrier. The bolts on the inside join the parts of the retaining frame together and must not be unscrewed.

M Disconnect negative and positive terminals on both batteries, see page 106.

M Unscrew bolts :. M Remove retaining frame ;. M Remove upper battery.


107


108

Electrical system

M Unscrew bolts =. M Remove retaining frame ?. M Remove lower battery. Installing batteries

M Install lower battery and fit retaining frame ?. M Secure retaining frame ? with bolts =. M Install upper battery and fit retaining frame ;. M Secure retaining frame ; with bolts :. M Connect positive and negative terminals on both batteries, see page 106.


Gearshift

Overview of gearshift Manual gearshift system (HPS) (see page 110)


Telligent ® gearshift system (see page 111)

Actros 1

Actros 2/3

Telligent ® automatic gearshift system and Mercedes PowerShift (see page 113)

Actros 1

Actros 2/3


109


Gearshift

Manual gearshift system The manual gearshift system (HPS) is a manually operated gearshift system. It is arranged as a double H shift. The shift ranges are divided into: • The low-speed shift range "L"; it comprises: • The reverse gear "R" • Forward gears 1 to 4 • The high-speed shift range "H"; it comprises: • Forward gears 5 to 8 • The splitter groups with the switch on the front of the gearshift lever. The additional gear ratios allow a total of 16 forward gears and 2 reverse gears to be shifted. The manual gearshift system (HPS) has two dedicated hydraulic circuits. The gears can be shifted hydraulically irrespective of the battery voltage and the compressed air supply. The spli tter group and range group are shifted electropneumatically.

Risk of accident

$

There is a risk of accident if there is a pressure loss in the ancillary consumer circuit. You may not be able to operate the clutch or change gears properly, and may not be able to escape from danger areas quickly enough. If the display shows : and the status indicator lights up yellow, do not start to move the vehicle or, if moving, stop it as quickly as possible taking into account the traffic situation. Have the compressed air system checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is ab solutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

110


Gearshift

Telligent® gearshift system The Telligent® gearshift system has 16 forward gears and 2 reverse gears. The gears can be selected either by the electronics or by the driver. A shift noise can be heard from the central speaker when each shift operation is completed.

$

Risk of accident

There is a risk of accident if there is a pressure loss in the ancillary consumer circuit. You may not be able t o operate the clutch or change gears properly, and may not be able to escape from danger areas quickly enough. If the display shows : and the status indicator lights up yellow, do not start to move the vehicle or, if moving, stop it as quickly as possible taking into account the traffic situation. Have the compressed air system checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work.


Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

Actros 1

d

Left-hand drive vehicles

e

Right-hand drive vehicles

:

Neutral button

;

Gearshift lever

Actros 2/3

• Move forwards: Upshift. • Move backwards: Downshift/reverse gear.

=

Function button

?

Half-gear switch • Pull up: Upshift 1/2 gear. • Push down: Downshift 1/2 gear.


111


Gearshift

Starting off Only 1st to 4th gear or reverse gear can be shifted from neutral in order to move off.

M Depress brake pedal or apply parking brake. M Fully depress clutch pedal. M Press function button =, hold down and push gearshift lever ; forward. The Telligent® gearshift system shifts to 1st gear (Actros 1) or 2nd gear (Actros 2/3). The gearshift is complete when a shift noise is heard from the central speaker and the display shows the engaged gear.

M Release brake pedal or parking brake. M Release clutch pedal and slowly depress accelerator pedal. Neutral position M Fully depress clutch pedal. The gearshift is complete when the display shows N.

M Depress brake pedal or apply parking brake. M Press and hold down neutral button :. The N indicator flashes in the display.

M Release clutch pedal and neutral button :. When the transmission is in neutral, only the splitter group is changed when the half-gear switch is pressed.

Reverse gear M Press and hold down function button =. M Pull gearshift lever ; backward until resistance can be felt. M Fully depress clutch pedal. The gearshift is complete when a shift noise is heard from the central speaker and the display shows R. Vehicles with backup warning system: The backup warning system sounds.

M Depress brake pedal or apply parking brake. M Release clutch pedal and slowly depress accelerator pedal.

112


Gearshift

Telligent® automatic gearshift system and Mercedes PowerShift

$

Risk of accident

There is a risk of accident if there is a pressure loss in the ancillary consumer circuit. You may not be able t o operate the clutch or change gears properly, and may not be able to escape from danger areas quickly enough. If the display shows : and the status indicator lights up yellow, do not start to move the vehicle or, if moving, stop it as quickly as possible taking into account the traffic situation. Have the compressed air system checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. Actros 1

Actros 2/3

• Telligent® automatic gearshift system (16-speed transmission)

• Telligent® automatic gearshift system (16-speed transmission) • Mercedes PowerShift (12-speed transmission) • Mercedes PowerShift (16-speed transmission)

d

Left-hand drive vehicles

e

Right-hand drive vehicles

:

Neutral button

?

Function button

;

Mode selector switch

A

Half-gear or gear switch

=

M

Manual mode

A

Automatic mode

Gearshift lever • Move forwards: Upshift. • Move backwards: Downshift/reverse gear.


• Pull up: 12-speed: Upshift 1 gear 16-speed: Upshift 1/2 gear • Push down: 12-speed: Downshift 1 gear 16-speed: Downshift 1/2 gear


113


Gearshift

Operating modes In vehicles without fleet mode and vehicles with 16speed transmissions you can choose between 2 operating modes. Vehicles with fleet mode are always in automatic mode. There is no mode selector button on the shift control unit. Automatic mode:

M Press mode selector button. or

M Move mode selector switch to position A. The display briefly shows auto.. The electronic system automatically controls the clutch operating system and shifts the gears in relation to: • • • • •

Vehicle load Engine speed Accelerator pedal position Operating state of the permanent brake Gradient of the road.

Manual mode:

M Press mode selector button. or

M Move mode selector switch to position M. The display briefly shows man.. The driver can now control the shift point and direction of every shift operation.

Risk of accident

$

When driving off-road or with the differential lock engaged in automatic mode A, shift operations p erformed by the electronic system can lead to undesirable interruptions of the tractive power. The power flow is interrupted and the vehicle may roll back on uphill gradients, for example, causing an accident. Never drive off-road with the differential lock engaged in automatic mode A. For this sort of driving, always select manual mode M in order to be able to initiate the gearchanges yourself according to the driving situation.

114


Gearshift

Starting off (automatic mode) M Depress brake pedal or apply parking brake. M Press function button ?, hold down and push gearshift lever = forward. The electronic system shifts to a suitable moving-off gear according to the vehicle load. The gearshift is complete when the display shows the engaged gear.

M Release brake pedal or parking brake and slowly depress accelerator pedal. Starting off (manual mode) M Depress brake pedal or apply parking brake. M Press function button ?, hold down and push gearshift lever = forward. The electronic system shifts • to 1st gear (Actros 1)


or • to 2nd gear (Actros 2/3, 16-speed transmission) or • to 3rd gear (Actros 2/3, 12-speed transmission) The gearshift is complete when the display shows the engaged gear.

M Release service or parking brake and slowly depress accelerator pedal. Neutral position M Depress brake pedal or apply parking brake. M Press neutral button :. The gearshift is complete when the display shows N.

Reverse gear M Depress brake pedal or apply parking brake. M Press function button ?, hold down and pull gearshift lever = backward until resistance can be felt. The gearshift is complete when a shift noise is heard from the central speaker and the display shows reverse gear. • R in vehicles with Telligent ® automatic gearshift system • R1 in vehicles with Mercedes PowerShift Vehicles with backup warning system: The backup warning system sounds.

M Release brake pedal or parking brake and slowly depress accelerator pedal.


115


Gearshift

Teach-in process Vehicles with Telligent® gearshift system, Telligent ® automatic gearshift system and Mercedes PowerShift: The teach-in process can be performed in order to restore proper operation following maintenance or repair work or after a fault. The reservoir pressure must be sufficient. The display message : must not be shown in the display. If the teach-in process is aborted prematurely, the display shows a message. In this case, make a note of the fault code for the service personnel (the fault code is not stored). If the gear control (GS) aborts the teach-in process:

M Turn the vehicle key in the ignition lock all the way back and wait at least 5 seconds. M Repeat teach-in process. In vehicles with Telligent® automatic gearshift system or Mercedes PowerShift, the clutch is operated automatically. Extract from fault code list, see page 119.

Minor teach-in process Vehicles with Telligent ® gearshift system

M Apply parking brake. M Turn the vehicle key in the ignition lock all the way back. M Fully depress clutch pedal within 3 seconds and hold down. M Press and hold down neutral button on shift control unit. M Turn vehicle key in ignition lock to drive position. A signal tone and a shift noise can be heard from the central speaker and the arrows for the splitter group in the display flash alternately.

M Release clutch pedal. A signal tone and a shift noise can be heard from the central speaker.

M Fully depress clutch pedal within 3 seconds and hold down. The teach-in process is complete when the display shows N.

M Release clutch pedal and neutral button on shift control unit. Vehicles with Telligent ® automatic gearshift system

M Apply parking brake. M Turn the vehicle key in the ignition lock all the way back. M Press and hold down neutral button on shift control unit. M Turn vehicle key in ignition lock to drive position. A signal tone and a shift noise can be heard from the central speaker and the arrows for the splitter group in the display flash alternately. The teach-in process is complete when the display shows N.

M Release neutral button on shift control unit.

116


Gearshift

Vehicles with Mercedes PowerShift

M Apply parking brake. M Turn the vehicle key in the ignition lock all the way back. M Press and hold down neutral button on shift control unit. M Turn vehicle key in ignition lock to drive position. A signal tone can be heard from the central speaker, the display shows N and the arrows for the splitter group flash alternately.

M Start engine. A signal tone can be heard from the central speaker. The teach-in process is complete when the display shows N.

M Release neutral button on shift control unit.



117


Gearshift

Major teach-in process The major teach-in process is necessary when • The GS control unit or the engine has been replaced • The display shows a message with the fault code a 2 1011. After the display: Turn the vehicle key in the ignition lock all the way back, wait about 5 seconds and then turn it back to the drive position. • The display shows a message with the fault code a 2 8093. Vehicles with Telligent ® gearshift system

M Apply parking brake. M Turn the vehicle key in the ignition lock all the way back. M Fully depress clutch pedal within 3 seconds and hold down. M Press and hold down neutral button and function button on shift control unit simultaneously. M Turn vehicle key in ignition lock to drive position. A signal tone and a shift noise can be heard from the central speaker and the arrows for the splitter group in the display flash alternately.


M Fully depress clutch pedal within 3 seconds and hold down. M When the display shows N, start the engine. A signal tone and a shift noise can be heard from the central speaker.


M Fully depress clutch pedal within 3 seconds and hold down. A signal tone and a shift noise can be heard from the central speaker.

M Release clutch pedal. M An acoustic signal and a shift noise can be heard from the central speaker. M Fully depress clutch pedal within 3 seconds and hold down. M The teach-in process is complete when the display shows N (large). M Release clutch pedal, neutral button and function button. Vehicles with Telligent ® automatic gearshift system or Mercedes PowerShift

M Apply parking brake. M Turn the vehicle key in the ignition lock all the way back. M Press and hold down neutral button and function button on shift control unit simultaneously. M Turn vehicle key in ignition lock to drive position. A signal tone can be heard from the central speaker, the display shows N (small) and the arrows for the splitter group flash alternately.

M Start engine. A signal tone can be heard from the central speaker and the display shows N (large).

118


Gearshift

M Release neutral button and function button. If the display messages do not disappear after the teach-in process, activate GS backup mode, (see page 128). Have the gearshift system checked at a q ualified specialist workshop, e.g. a Mercedes-Benz service center.

Extract from fault code list Fault code

Cause

Remedy

GS 06-GS 18 / GS 27/ GS 29/ GS 32

Teach-in errors

M Repeat teach-in process.

GS 19

Vehicle rolling.


GS 20

The display shows U <<<.

M Charge or replace the battery.

GS 21

The clutch pedal was released too early M Depress and release the clutch pedal at the right time (listen for the warning buzzer). or too late during the teach-in process.

GS 22

The neutral button was not released during the teach-in process.

M Press and hold down neutral button.

GS 23

Teach-in errors

M Perform major teach-in process.

GS 24

Parking brake not applied during the teach-in process.


GS 25

Emergency shift operated during teach-in process.

M Do not operate emergency shift.

GS 26

Engine running

M Minor teach-in process: Switch off the engine.

If this fault code reappears after the teach-in process, have the fault rectified at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work.


M Major teach-in process: Do not start the engine until the transmission neutral position N flashes. GS 28

Engine was not started.

M Do not start the engine until the transmission neutral position N flashes.

GS 30 GS 31

The accelerator pedal was depressed during the teach-in process.

M Do not depress the accelerator pedal during

The clutch pedal was not fully depressed during the teach-in process.

M Repeat teach-in process.

the teach-in process.


119


Gearshift

Emergency shift of manual gearshift system (HPS)

1 2

3

4

:

Shift transmitter

=

Gear cylinder

;

Expansion reservoir

?

Gate cylinder

Risk of injury

$

Perform the emergency shift at the transmission only when the vehicle is stationary, the parking brake is applied and the engine is off. The vehicle key in the ignition lock must be turned all the way back. If a gear is engaged while the engine is running, this can cause transmission damage and the vehicle may move off suddenly and uncontrollably. You may be seriously injured. If the HPS is defective, you can shift 3rd or 4th gears or reverse gear manually using the gear and gate levers on the transmission. 4th gear permits you to start the vehicle moving in order to reach a qualified specialist workshop. Mercedes-Benz recommends a Mercedes-Benz service center for this work because this possesses the required expertise and tools in order to perform the necessary work.

! The manually engaged gear cannot be changed while driving. Depending on the vehicle model and equipment, it may be necessary to tilt the cab in order to gain access to the gear and gate levers. Tilting the cab, see page 157.

120


Gearshift

Tools The necessary tools can be found in the vehicle tool bag.

Gear

Tool

3, 4

Open end wrench, size 34 mm, or adjustable pliers

R

Second open end wrench, size 34 mm, or second adjustable pliers

Shifting 3rd and 4th gears M Turn the vehicle key in the ignition lock all the way back.

M Apply parking brake. M If necessary, tilt the cab, see page 157.


(Gate lever on left side of transmission)

M If a gear is engaged, move the gear lever on the right side of the transmission to neutral position A.

M If 5th – 8th gear was engaged, move the gate lever on the left side of the transmission to position ;.

M To engage 3rd gear, move the gear lever to position B. M To engage 4th gear, move the gear lever to position ?. The gear is engaged when the shift shaft is felt to engage in the corresponding position. (Gear lever on right side of transmission)

Starting off

! You can only drive in the engaged gear. It is not possible to change gears while driving. When you stop, you must keep the clutch pedal fully depressed.

M Fully depress clutch pedal and start engine. M Release parking brake. M Slowly release clutch pedal and slowly depress accelerator pedal.


121


Gearshift

Shifting reverse gear ! In order to shift reverse gear, the help of a second person is necessary.


M Apply parking brake. M If necessary, tilt the cab, see page 157.

(Gate lever on left side of transmission)

If a gear is engaged, move the gear lever on the right side of the transmission to neutral position A. 1st person:

M Push the gate lever on the left side of the transmission forward as far as the stop : and hold in this position. 2nd person:

M Move gear lever on right side of transmission to position ?. The gear is engaged when the gear lever is felt to engage in position ?. Starting off

(Gear lever on right side of transmission)


M Fully depress clutch pedal and start engine. M Release parking brake. M Slowly release clutch pedal and slowly depress accelerator pedal.

122


Gearshift

Emergency shift of Telligent® gearshift system and Telligent® automatic gearshift system (Actros 1) General information On vehicles with Telligent® gearshift system and Telligent® automatic gearshift system, an emergency shift can be performed at the shift control unit or at the transmission. On vehicles with Telligent® automatic gearshift system, the clutch pedal must be folded out before operating the emergency shift. A malfunction in the automatic clutch operating system is indicated by the malfunction display "Fold out clutch pedal". At the same time the warning buzzer sounds.

:

Up to 12/1999

;

As of 01/2000


Folding out clutch pedal M Turn vehicle key in ignition lock to drive position; the warning buzzer sounds.

1

M Pull release lever : down. The clutch pedal ; automatically swings into the driver footwell and locks in place. The warning buzzer should stop.

M Fully depress clutch pedal ; twice. M Shift transmission to neutral and start engine. M Perform gearchange manually. M The clutch pedal ; must be fully depressed for each gearchange.

2


123


Gearshift

Emergency shift at shift control unit (Vehicles with Telligent® gearshift system or Telligent® automatic gearshift system)

M Swing cover : of emergency switch up. The emergency switch is inoperative in normal mode, even if it can be pressed. A changeover from normal mode to emergency shift can only occur if: • • • •

The emergency switch is in the basic position n The vehicle is stationary The clutch is disengaged A malfunction is present

Before the emergency shift is performed, the emergency switch must be in the basic position n. The following codes may be shown in the display: • Up to manufacture year 12/1999: "GS 01" = Emergency shift not in basic position "GS 02" = Emergency shift active "GS 03" = No gear indication possible "GS 04" = Emergency shift not possible • As of manufacture year 01/2000: "GS 01" = Emergency shift not in basic position "GS 02" = Emergency shift active While driving it is only possible to change from 2nd to 5th gear. The individual shift positions can only be engaged in sequence and gears can only be shifted from the transmission neutral position (n, b or c). If the display shows the warning Ancillary consumer reservoir pressure, run the engine to fill the compressed air system. If it is not possible to perform the emergency shift with the emergency switch, perform the emergency shift at the transmission, see page 126.

124


Gearshift

Shift positions of emergency shift

n

Basic position (transmission in neutral)

2

2nd gear

b

Neutral (low-speed range group)

c

Neutral (high-speed range group)

5

5th gear

k

Reverse gear

M Fully depress clutch pedal and hold down. M Start engine. Shifting to neutral:

M If a gear is engaged, press down emergency switch in position n (basic position) and hold down for


about 1 second. Release emergency switch. Shifting to 2nd gear

M Press down emergency switch in position n and hold down for about 1 second. M Turn emergency switch to position 2 and again hold for about 1 second. M Release emergency switch. Shifting to 5th gear

M Press down emergency switch in position 2 and hold down for about 1 second. M Turn emergency switch to position b and again hold for about 2 seconds. M Release emergency switch. M Press down emergency switch in position b and hold down for about 1 second. M Turn emergency switch to position c and again hold for about 2 seconds. M Release emergency switch. M Press down emergency switch in position c and hold down for about 1 second. M Turn emergency switch to position 5 and hold for about 2 seconds. M Release emergency switch. Shifting to reverse gear:

M Press down emergency switch in position n and hold down for about 1 second. M Turn emergency switch to position k and again hold for about 1 second. M Release emergency switch. Engaging the clutch and starting off:

M Gradually release clutch pedal. M To move off, slowly depress accelerator pedal.


125


Gearshift

Emergency shift at transmission Risk of injury

Perform the emergency shift at the transmission only when the vehicle is stationary, the parking brake is applied and the engine is off. The vehicle key in the ignition lock must be turned all the way back. If a gear is engaged while the engine is running, this can cause transmission damage and the vehicle may move off suddenly and uncontrollably. You may be seriously or fatally injured.

:

Adapter for transmission shift shaft

;

"3/4" adjusting screw

The special tool for the emergency shift is in the vehicle document wallet.

M If necessary, tilt the cab forward, see page 157. M Always turn the shift shaft from the transmission neutral position (N) (center position) all the way to the stop. Do this using the adapter for the transmission shift shaft :.

M If the shift shaft fails to engage at the stop, turn the shift shaft to the center position and repeat the shift operation.

! You can only drive in the engaged gear. It is not possible to change gears while driving. When you stop, you must keep the clutch pedal fully depressed. The gear indicator in the display may fail. Shifting 1st or 2nd gear

M Fit adapter for transmission shift shaft : on shift shaft.

M Turn shift shaft clockwise =. G210, G 211: 1st gear is engaged. G240, G 260: 2nd gear is engaged. or

M Turn shift shaft counterclockwise ?. G210, G 211: 2nd gear is engaged. G240, G 260: 1st gear is engaged.

126

$


Gearshift

3rd or 4th gear

M Unscrew screw plug A from shift shaft. M Screw "3/4" adjusting screw ; all the way into shift shaft and tighten.

M Fit adapter for transmission shift shaft : on shift shaft.

M Turn shift shaft clockwise =. G210, G 211: 3rd gear is engaged. G240, G 260: 4th gear is engaged. or

M Turn shift shaft counterclockwise ?. G210, G 211: 4th gear is engaged.


G240, G 260: 3rd gear is engaged. Reverse gear

M Unscrew screw plug A from shift shaft. M Screw "R" adjusting screw (special tools, see page 196) all the way into shift shaft (about 18 turns), then unscrew max. 1/4 turn.

M Fit adapter for transmission shift shaft : on shift shaft. M Turn shift shaft counterclockwise ?. Starting off in the engaged gear


M Depress clutch pedal. M Start engine. M Release parking brake. M Slowly release clutch pedal and slowly depress accelerator pedal.


127


Gearshift

Emergency shift of Telligent ® gearshift system, Telligent® automatic gearshift system or Mercedes PowerShift (Actros 2/3) If there is a malfunction in the electronic gearshift, the vehicle can only be driven in emergency mode (GS backup mode). To do this, you must enable the function GS back-up mode in the onboard computer. In GS back-up mode the shift positions of the transmission are shifted using the buttons on the multifunction steering wheel. Vehicles with Telligent® automatic gearshift system or Mercedes PowerShift: The vehicle can be expected to behave sluggishly when starting off or stopping. Shift options in GS back-up mode: • • • •

Low gear or high gear Reverse gear Transmission neutral Towing mode.

In GS back-up mode you can only drive in the engaged gear. It is not possible to change gears while driving. When you stop, you must keep the clutch pedal fully depressed.

Enabling GS back-up mode M Stop the vehicle and switch off, taking into account the traffic situation. M Apply parking brake. M Start engine. M Press buttons on multifunction steering wheel. Description

1 VU

Main menu – Settings

2 WX

Configuration

3 &*

Enable GS back-up mode

4 WX

On

Enable GS back-up mode

GS back-up mode remains enabled for as long as the vehicle key i n the ignition lock remains in the drive position. When the vehicle key in the ignition lock is turned all the way back, GS back-up mode is disabled again automatically.

128


Gearshift

GS back-up mode: Vehicles with Telligent® gearshift system Starting off

Gear indicator

Description

GS back-up mode activated

1 VU

GS back-up mode Engage parking brake before gear selection

N

2 &*

Select gear Low gear/High gear

N

3 WX


N

4 &*

Depress clutch Clutch depressed?/Yes/No

N

5 Fully depress clutch pedal.


N

6 WX

Yes

N

7 &*


2, 5 or R

8 Release clutch pedal and slowly depress accelerator pedal.


2, 5 or R

Vehicle moves off

Gear indicator

Description

Stop the vehicle. Observe the traffic situation. It is not possible to change gears while driving.

Select gear (5, 2, R)


Confirm

Stopping, changing gear or transmission in neutral

1 Depress clutch pedal. 2 Brake vehicle to a standstill with brake pedal.


5, 2, N or R

3 &*

Select gear

5, 2, N or R


129


130

Gearshift

If the display shows Driving in GS back-up mode – Manual gearshift only possible to N, stop the vehicle. While driving it is only possible to change to the transmission neutral position N with a gear engaged. In GS backup mode the selected gear may not appear in the display if the transmission is cold. In this case it may be necessary to repeat the gear selection several times. If there is no gear shown in the display after repeated gear selection, switch off and restart the engine and reactivate GS back-up mode. Towing mode

Gear indicator

Description


1 VU


N

2 &*

Select gear Low gear/High gear/N/R/Towing

N

3 WX

Select gear Towing

N

4 &*


N

5 Fully depress clutch pedal.


N

6 WX

Yes

N

7 &*

GS back-up mode Towing

N

8 Release clutch pedal.


N


Select Towing

Confirm

Towing mode is activated

Gearshift

GS back-up mode: Vehicles with Telligent® automatic gearshift system or Mercedes PowerShift Starting off

M Select manual mode M. Gear indicator

Description


1 VU


N

2 &*


N

3 WX


N


2, 5 or R1


2, 5 or R1

4 &*

5 Slowly depress accelerator pedal. 1

16-speed transmission

2



Select gear (5, 2, R) 1 Select gear (7, 1, R) 2

1, 7 or R2

Vehicle moves off

1, 7 or R2

Stopping, changing gear or transmission in neutral

Gear indicator Description

1 Brake vehicle to a standstill with brake pedal.


2, 5, N or R1

2 &*

Select gear N

2, 5, N or R1

1


2


1, 7, N or R2

Stop the vehicle. Observe the traffic situation. It is not possible to change gears while driving.

1, 7, N or R2

If the display shows Driving in GS back-up mode – Manual gearshift only possible to N, stop the vehicle. While driving it is only possible to change to N with a gear engaged. In GS back-up mode the selected gear may not appear in the display if the transmission is cold. In this case it may be necessary to repeat the gear selection several times. If there is no gear shown in the display after repeated gear selection, switch off and restart the engine and reactivate GS back-up mode.


131


Gearshift

Towing mode

M Select automatic mode A. Gear indicator

Description


1 VU


N

2 &*

Select gear Towing

N

3 WX

Select gear Towing

N

Select Towing

4 &*


N

Towing mode is activated

Manual emergency shift at transmission The manual emergency shift in the Actros 2/3 can be performed using the special tool "adapter for transmission shift rod". Special tools, see page 196. Description of emergency shift, see page 126.

132


Gearshift

Emergency shift (live PTO) If the live power take-off fails, it is possible to create a rigid power transmission connection in the power take-off.

:

Retainer

;

Slotted nut

=

Threaded hole for retainer

Risk of injury

$

Perform the emergency shift of the transmissionindependent PTO only when the vehicle is stationary, the parking brake is applied and the engine is off.


The shaft could cause you serious injury if the engine is running.

M Unscrew retainer :. M Unscrew slotted nut ; as far as the stop, about 4.5 turns.

+ If the slotted nut ; is stiff, turn the drive shaft a little.

M Secure slotted nut ; with retainer : by turning the retainer : over and screwing it into a suitable threaded hole =.


133


Compressed air production

Versions :

Electrical connection of reservoir pressure sensors for brake circuits 1 and 2

The following compressed air production systems may be installed depending on the vehicle version: • Pressure regulating system: The air drier with integrated pressure regulator and the four-circuit protection valve are two separate components. The pressure for brake circuits 1 and 2 is not limited in the four-circuit protection valve, but corresponds to the shutoff pressure of the pressure regulator in the air drier.

Pressure regulating system

• Conventional constant pressure system: The air drier with integrated pressure regulator and the four-circuit protection valve are two separate components. The pressure for brake circuits 1 and 2 is limited in the four-circuit protection valve. • Constant pressure system with Electronic AirProcessing Unit (EAPU): The pressure regulator, compressed air drier, multi-circuit protection valve, pressure limiting valves and control electronics are combined in one mechatronic unit.

Conventional constant pressure system

The pressure regulating system and the conventional constant pressure system are very similar externally. They can be distinguished by the electrical connection of the reservoir pressure sensors for brake circuits 1 and 2 :. On the pressure regulating system this is located at the side of the four-circuit protection valve while on the conventional constant pressure system it is at the top of the four-circuit protection valve.

Constant pressure system with Electronic Air-Processing Unit (EAPU)

134



Pressure regulating system The compressed air is produced by the engine-driven compressor (single-cylinder or dual compressor) and then flows to the air drier with integrated pressure regulator (single-chamber or dual-chamber air drier). Here the compressed air is dried and limited to the set value. From the air drier the compressed air travels to the four-circuit protection valve. Here the compressed air is split into 4 circuits and the pressure in circuits 3 and 4 is limited to 8.5 bar. The pressure for brake circuits 1 and 2 is not limited, but corresponds to the shutoff pressure of the pressure regulator in the air drier. The compressed air flows through the outlets of the four-circuit protection valve to the compressed air reservoirs. At the four-circuit protection valve are the reservoir pressure sensors for brake circuits 1 and 2. These register the pressures that are displayed in the Instrument. In addition, the four-circuit protection valve protects the intact pressure circuits against a potentially defective pressure circuit. The air drying is monitored by a condensation sensor mounted on the compressed air reservoir of brake circuit 2. Since 31.05.2005 the compressed air reservoir of brake circuit 2 is also fitted with a safety valve to dissipate the overpressure (only on compressed air reservoirs with an operating pressure < 15.5 bar – aluminum tanks).


Constant pressure system with separate four-circuit protection valve The compressed air is produced by the engine-driven compressor (single-cylinder or dual compressor) and then flows to the air drier with integrated pressure regulator (single-chamber or dual-chamber air drier). Here the compressed air is dried and limited to the set value. From the air drier the compressed air travels to the constant compressed air reservoir, at which a condensation sensor monitors the drying of the air. Since 31.05.2005 the constant compressed air reservoir is also fitted with a safety valve to dissipate the overpressure (only on compressed air reservoirs with an operating pressure < 15.5 bar – aluminum tanks). The compressed air then travels to the four-circuit protection valve. Here the compressed air is split into 4 circuits and the pressure is limited: to 10 bar in brake circuits 1 and 2, and to 8.5 b ar in circuits 3 and 4. The compressed air flows through the outlets of the four-circuit protection valve to the compressed air reservoirs. At the four-circuit protection valve are the reservoir pressure sensors for brake circuits 1 and 2. These register the pressures that are displayed in the Instrument. In addition, the four-circuit protection valve protects the intact pressure circuits against a potentially defective pressure circuit.


135



Constant pressure system with Electronic Air-Processing Unit (EAPU) The Electronic Air-Processing Unit (EAPU) is a development of the conventional compressed air supply system. It is available in the Actros 3 (model designation 934 only). The following components are combined in one mechatronic unit: • • • • •

Pressure regulator Compressed air drier Multi-circuit protection valve Pressure limiting valves Control electronics Electronic Air-Processing Unit

The engine-driven, switchable compressor (single-cylinder or dual compressor) produces the compressed air. The air flows through the compressed air line for cooling before arriving in the Electronic Air-Processing Unit. Here the compressed air is filtered and dried by the air dr ier cartridge. It is then distributed between the brake and ancillary consumer circuits, as well as the circuit for the air suspension. The pressures in the pressure circuits are monitored by pressure sensors and any faults are reported to the driver via the base module and the Instrument. In the event of a defective pressure circuit, the Electronic Air-Processing Unit protects those air circuits that are still intact. The Electronic Air-Processing Unit controls and regulates all functions according to their set specifications and with reference to the information provided by the pressure sensors and by the networked vehicle systems. Via the compressed air connections (21 to 27) on the Electronic Air-Processing Unit the compressed air flows into the compressed air reservoirs or directly into the various pressure circuits. A condensation sensor is mounted on compressed air reservoir V2 (front axle brake circuit supply). If condensation is present, the driver is notified via the Instrument. In the case of compressed air reservoirs with a test pressure PD < 15.5 bar, the compressed air reservoir V2 is also fitted with a safety valve to protect the compressed air system against overpressure. The pressure in the supply circuits is 12.5 bar. The pressure in the brake circuits is limited by the brake control. The Electronic Air-Processing Unit is integrated into the vehicle network and i s diagnosable via the CAN bus. The part numbers, measurement values, binary values and the fault memory can be read out. For optimum control, the type of compressor (single-cylinder or dual compressor) is also stored.

136



Pressure table The pressure values stabilize only when the ignition is on and may be slightly higher when new in order to compensate for the relaxation losses anticipated in use.

Pressure regulating system

Conventional constant pressure system

Conventional constant pressure system with Electronic AirProcessing Unit

Operating pressure, rear and front axle brake circuit supply (connections 21 and 22)

9.8...10.6 bar

9.5...10.7 bar

10.7...13.3 bar

Operating pressure, trailer control, ancillary consumers, parking brake and transmission control supply, clutch operating system (connections 23 to 26)

8.0...8.7 bar

8.0...8.7 bar

7.4...8.5 bar

Opening pressure, rear and front axle brake circuit supply (connections 21, 22)

8.7...9.0 bar

8.7...9.0 bar

8.7...9.0 bar

Closing pressure, 1front and rear axle brake circuit supply (connections 21, 22)

min. 4.5 bar

min. 4.5 bar

min. 4.5 bar

Opening pressure, trailer control and parking br ake (connections 23, 25)

7.2...7.5 bar

7.2...7.5 bar

6.7...7.0 bar

Closing pressure1, trailer control and parking brake (connections 23, 25)

min. 4.5 bar

min. 4.5 bar

min. 4.5 bar

Opening pressure, ancillary consumers (connection 24)

7.2...7.5 bar

7.2...7.5 bar

7.2...7.5 bar

Closing pressure1, ancillary consumers (connection 24)

min. 4.5 bar

min. 4.5 bar

min. 4.5 bar

Opening pressure, transmission control, clutch operating system (connection 26)

---

---

6.2...6.5 bar

Closing pressure1, transmission control, clutch operating system (connection 26)

---

---

min. 4.5 bar

Release pressure (reservoir pressure in compressed air system)

min. 8.0 bar

min. 8.0 bar

min. 8.0 bar

Release pressure (with external compressed air source)

min. 6.5 bar

min. 6.5 bar

min. 6.5 bar

Operating pressures


Opening and closing pressures

Spring-loaded actuator

1

Closing pressure = static safety pressure (without replenishment and with 0 bar in the defective circuit)


137


Brake system

General

Risk of accident

$

Leaks in the compressed air brake system put the operational safety of the vehicle at risk. If the reservoir pressure in the compressed air brake system is too low, it is not possible to b rake the vehicle or change gear. You could cause an accident with possible injury to yourself and others. Do not set the vehicle in motion until the required reservoir pressures have been reached and the STOP lamp has gone out. If the display shows J, do not start to move the vehicle or, if moving, stop it as quickly as possible taking into account the traffic situation. In addition, the status indicator lights up red and the STOP lamp does not go out. Have the brake system checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is ab solutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. Different brake systems may be installed depending on the vehicle equipment. The dual-circuit pneumatic brake with antilock brake system is standard equipment in the Actros 1/2, the Telligent ® brake system is available as special equipment in the Actros 1/2 and standard in the Actros 3.

Telligent® brake system The Telligent® brake system is an electronically controlled and monitored pneumatic brake system. It consists of a purely pneumatic dual-circuit brake system, which is actuated by the electronic brake control. The electronic brake control is superimposed on the conventional, purely pneumatic control of the service brake and supplements it with the following functions: • • • • •

Antilock brake system (ABS) Acceleration skid control (ASR) Automatic load-dependent brake pressure control (ALB) Hill holder (as of Actros 3) Brake Assist (as of Actros 3)

If the electronic system fails, the brake system is controlled pneumatically in two circuits. Braking behavior is significantly different from that of the i ntact system. The ABS function is no longer available, the pedal travel is longer and the pedal forces are higher. To relieve the strain on the wheel brakes the Telligent ® brake system can activate the permanent brake depending on the load state of the vehicle and the weather conditions.

138


Brake system

Frequent-stop brake

$

Risk of accident

The parking brake must be applied in order to switch off the engine. Otherwise the vehicle can roll away unintentionally. If necessary (e.g. on uphill or downhill gradients), secure the vehicle with wheel chocks.

d

Actros 1

e

Actros 2/3

:

Frequent-stop brake indicator lamp

;

Frequent-stop brake switch


The frequent-stop brake is intended for vehicles which perform a high proportion of stop-and-start procedures (garbage trucks etc.). It is activated by the driver via the frequent-stop brake switch ; and then remains on standby. Activation/standby is displayed via the indicator lamp : in the Instrument. The function is activated by operating the brake pedal. While the vehicle is stationary, the diaphragm brake cylinders of the service brake on all axles are pressurized via a solenoid valve. A constant minimum brake pressure of approx. 3.5 bar secures the vehicle to prevent it from rolling. When the vehicle starts off, the br akes open automatically. It is not necessary to release the b rakes manually. In comparison with the hill holder, which acts exclusively as a starting-off aid, the frequent-stop brake maintains the b rake pressure even when the clutch or brake pedal is not operated. The frequent-stop brake requires less compressed air than the parking brake.

Switching on/activating the frequent-stop brake M Press top of frequent-stop brake switch ;. The indicator lamp : in the instrument panel lights up. The frequent-stop brake is standing by, but is not yet active.

M Brake vehicle to a standstill. The frequent-stop brake is active. If you release the service brake and turn the vehicle key in the ignition lock all the way back with the frequentstop brake activated, the warning buzzer sounds. In addition the indicator lamp : in the instrument panel flashes.



139


Brake system

Releasing the frequent-stop brake M Depress accelerator pedal. When the vehicle moves off, the frequent-stop brake is released automatically and is on standby again.

Deactivating the frequent-stop brake M Press bottom of frequent-stop brake switch ;. The indicator lamp : in the instrument panel goes out.

Safety valve (Only for Actros 1 vehicles delivered to Norway and Sweden.) If the reservoir pressure in the spring-loaded brake circuit drops below 4.0 bar, the safety valve : is automatically turned to the shutoff position. The vehicle is braked automatically with the springloaded parking brake (even if the parking brake l ever is in the release position). This prevents any unintentional release of the parking brake due to another pressure rise in the spring-loaded actuator. In order to ensure that the parking brake releases properly, the reservoir pressure (service brake circuits) must be at least 8 bar. The STOP lamp and the reservoir pressure warning indicator must not be lit.

M Turn safety valve to the right to release position. The safety valve cannot be turned to the release position until the pr essure in the spring-loaded brake circuit has risen above 4.0 bar.

M Lift the lock on the parking brake valve and swing the lever all the way forward. The parking brake release indicator lamp must go out. If the reservoir pressure in the spring-loaded brake circuit is insufficient, the spring-loaded parking brake can be released mechanically or pneumatically.

Active Brake Assist (ABA) (Only in Actros 3 vehicles.) The Active Brake Assist is an assistance system for critical driving situations. Active Brake Assist can help to minimize the danger of a collision with vehicles in front or at least to reduce the consequences of a collision. Active Brake Assist is merely an aid to assist you while driving. When Active Brake Assist detects a dangerous situation, the driver is warned acoustically and visually. If there is danger of a collision, automatic partial braking is initiated as an additional second warning stage.

140


Brake system

If the driver fails to react to the warnings, Active Brake Assist automatically triggers an emergency stop (full braking).

+ When the Telligent® adaptive cruise control is on, the warnings of the Telligent ® adaptive cruise control appear first, and then those of the Active Brake Assist. When the Telligent ® adaptive cruise control is off, only the warnings of the Active Brake Assist appear.

$

Risk of accident Active Brake Assist does not absolve you from adapting your driving style to suit the traffic and road conditions.

The responsibility for the speed driven, the timely initiation of braking or evasive maneuvers and the keeping of a safe distance always lies with the driver. Active Brake Assist does not adapt automatically to road and traffic conditions. Brake the vehicle with the service brake if:


• The display shows the symbol · with a red status indicator • A constant warning tone sounds • A constant warning tone sounds and automatic partial braking is initiated The deceleration provided by the Active Brake Assist may not be sufficient to avoid a collision with the vehicle in front.

$

Risk of accident

Active Brake Assist issues warnings and brakes the vehicle only for preceding vehicles, not for oncoming traffic or stationary obstructions on the road, such as broken-down vehicles or the end of a tailback with stationary vehicles. It cannot always clearly identify complex driving situations. If a visual and/or acoustic warning or partial braking occurs in a non-critical situation, you can switch off the system by operating • • • •

the turn signal lever the brake pedal the accelerator pedal or the Active Brake Assist OFF switch

If Active Brake Assist has already initiated an emergency stop, this can be aborted by actuating the kickdown (accelerator pedal depressed beyond the actuation point) or the Active Brake Assist OFF switch. If you do not receive a visual and acoustic warning in a critical situation, then either Active Brake Assist has not recognized the danger of the situation, or i t is switched off or has failed. Brake the vehicle wi th the service brake.


141


Brake system

Switching Active Brake Assist on/off :

Active Brake Assist OFF switch

;

Indicator lamp

Active Brake Assist is switched on automatically.

M Turn vehicle key in ignition lock to drive position. The indicator lamp ; in the Active Brake Assist OFF switch goes out. Active Brake Assist is switched off automatically: • At speeds below 10 km/h • Vehicles with air suspension: If the chassis is not at normal level • In the event of a fault in the Active Brake Assist electronics • If the antilock brake system is switched off or there is a fault in the brake system of the vehicle. The display shows n and 6 with a yellow status indicator. Switching off

M Press top of Active Brake Assist OFF switch :. The indicator lamp ; in the switch lights up. The display briefly shows ç and Active Brake Assist switched off with a white status indicator.

+ When the engine is restarted, the Active Brake Assist is switched back on automatically. Switching on

M Press top of Active Brake Assist OFF switch :. The indicator lamp ; in the switch goes out. The display briefly shows ç and Active Brake Assist switched on with a white status indicator.

+ If the indicator lamp ; in the Active Brake Assist OFF switch : lights up, there may be a malfunction. This malfunction may be in the Active Brake Assist or in the vehicle's brake system. If the indicator lamp ; in the Active Brake Assist OFF switch : also lights up when the antilock brake system is off. When you press the switch, the display briefly shows ç and Active Brake Assist cannot be activated with a white status indicator alternating with other event messages.

142


Brake system

Location of components (example: semitrailer variant)

:

Front compressed air filler connection (special equipment for Actros 2/3)

D

Trailer control valve

;

Compressor

E

Regeneration compressed air reservoir

=

Compressed air reservoir (front axle service brake)

F

Four-circuit protection valve1

?

Combination brake cylinder

G

Air drier with integrated pressure regulator1

A

Compressed air reservoir (trailer/semitrailer brake)

H

Constant pressure reservoir

B

Compressed air reservoir (clutch operating system/gearshift)

I

Front coupling head (special equipment for Actros 1)

C

Compressed air reservoir (rear axle service brake)

1


Location: On the implement carrier or on the inside of the frame (special equipment).


143


Brake system

Filling the brake system from an external source If the engine is not running, you can fill the brake system via the following components: • • • • •

Compressed air filler connection on air drier (vehicles without Electronic Air-Processing Unit) Compressed air filler connection on Electronic Air-Processing Unit (EAPU) Front coupling head (special equipment for Actros 1) Front compressed air filler connection (special equipment for Actros 2/3) Tire inflation connection

! The maximum filling pressure of 12.5 bar must not be exceeded. To ensure proper filling, the pressure regulator of the vehicle to be filled must switch on. Reduce the pressure to below 9 bar if necessary.

+ Compressed air can be released e.g. by operating the service brake repeatedly. Before towing, check that the spring-loaded actuators of the parking brake are released. If the compressed air supply is insufficient, release the spring brake cylinders mechanically, see page 150. Separate filling of the air suspension system, see page 156.

144


Brake system

Filling via the air drier/Electronic Air-Processing Unit (EAPU) :

Screw plug

The four-circuit protection valve, the air drier or the Electronic Air-Processing Unit (EAPU) are usually located on the vehicle frame on the left side. On semitrailer tractors the four-circuit protection valve, the air drier or the Electronic Air-Processing Unit (EAPU) may be installed inside the frame. Detach any covers if necessary.

M If a compressed air filler connection is not already present: Unscrew screw plug : and screw in compressed air filler connection. Leave the compressed air filler connection installed in place of the screw plug :.

Vehicles with single-chamber air drier


M Connect filling hose to compressed air filler connection.

M Only on vehicles with Electronic Air-Processing Unit (EAPU): Switch on ignition.

M Fill compressed air reservoir via the compressed air filler connection.

Vehicles with dual-chamber air drier

Vehicles with Electronic Air-Processing Unit (EAPU)


145


Brake system

Filling via the front coupling head/front compressed air filler connection (special equipment) Actros 1 The coupling head ; is behind a flap on the lefthand side of the bumper.

2

Actros 2/3 The filler connection : is in a cutout on the righthand side of the bumper.

146


Brake system

Filling via the tire inflation connection :

Tire inflation connection

The brake system should only be filled via the tire inflation connection : in an emergency as the compressed air is neither cleaned nor dried and there is no protection against overpressure.

! Compressed air that has not been cleaned and dried can lead to malfunctions or damage in the compressed air system. When filling the compressed air system, make sure that no di rt and no damp air is allowed to enter the compressed air system.

Vehicles with single-chamber air drier


The four-circuit protection valve, the air drier or the Electronic Air-Processing Unit (EAPU) are usually located on the vehicle frame on the left side. On semitrailer tractors the four-circuit protection valve, the air drier or the Electronic Air-Processing Unit (EAPU) may be installed inside the frame. Detach any covers if necessary.

Vehicles with dual-chamber air drier

Vehicles with Electronic Air-Processing Unit (EAPU)


147


Brake system

Releasing the spring-loaded parking brake If the compressed air supply is insufficient, the spring-loaded parking brake can be released pneumatically via an external compressed air source or mechanically.

Releasing the spring-loaded parking brake pneumatically Risk of accident

Before releasing the spring-loaded parking brake, secure the vehicle with wheel chocks to prevent it from rolling. The spring-loaded cylinders of the parking brake must be restored to the operational state before the vehicle is operated. If it is not possible to fill the system via the air dri er/ Electronic Air-Processing Unit (EAPU) or front coupling head/front compressed air filler connection, circuit 3 can be filled via the filling valve. On vehicles as of mid-2000, the filling valve is replaced by a test connection. Do not confuse the filling valve ; with a test connection :. The filling valve ; has a red dust cap with a wide rubber lip. The rubber lip bears the inscription "Emergency release connection". When the dust cap is removed, you will see the valve which is flush with the threaded connection. The valve in the test connection : protrudes. Location of filling valves/test connections for circuit 3 on the implement carrier

148

$


Brake system

Location of filling valves/test connections for circuit 3 on the four-circuit protection valve

– Actros 1/2 with single-chamber air drier and constant pressure system – Actros 3 with single-chamber air drier without integral rear end

Actros 1/2 with single-chamber air drier and pressure regulating system


Location of filling valves/test connections for circuit 3 on the compressed air reservoir The compressed air reservoirs may be located in other positions depending on equipment installed.

– Actros 1/2 with dual-chamber air drier and constant pressure system – Actros 3 with dual-chamber air drier without integral rear end

Actros 3 with integral rear end


149


Brake system

Releasing the spring-loaded parking brake mechanically In an emergency, if there is insufficient reservoir pressure in the brake system, the spring brake cylinders can be released mechanically to allow the vehicle to be towed away.

$

Risk of accident

Before releasing the spring-loaded parking brake, secure the vehicle with wheel chocks to prevent it from rolling. Attach a clearly visible sign on the mechanically released spring-loaded parking brake in the vehicle interior. The spring-loaded cylinders of the parki ng brake must be restored to the operational state before the vehicle is operated. The vehicles may be equipped with different spring brake cylinders on each axle. Spring brake cylinders with release screw or with release indicator may be installed.

Spring brake cylinder with release screw

:

Driving position

;

Release position

Spring brake cylinder with release indicator

M Secure vehicle using wheel chocks to prevent it from rolling. Releasing the spring brake cylinders mechanically Release all the spring brake cylinders on the vehicle.

M Turn the release screws all the way counterclockwise to the release position ;. ! Slacken the release screw with a maximum torque of 70 Nm. Do not use an impact wrench. Otherwise the spring brake cylinder could be damaged.

+ Use a wrench with a size of 24 mm. The slackening travels of the release screws are as follows: • Vehicles with 4 x 2 axle configuration: 40 mm • Vehicles with 4 x 4 axle configuration in combination with disk brakes and spring brake cylinders on the front axle: 40 mm • All other vehicles: 60-65 mm

150


Brake system

Restoring spring brake cylinders to driving position Restore all the spring brake cylinders to the driving position :.

M Clean and grease release screws before screwing in. M Fill brake system up to cutoff pressure. M Swing lever of parking brake all the way to the release position. M Turn the release screw of the spring brake cylinder clockwise to the driving position :. M Tighten release screws. ! Tighten the release screws with a maximum torque of 35 Nm. Do not use an impact wrench. Otherwise the spring brake cylinders could be damaged.



151


152


Diagram of Telligent® level control

:

Telligent® level control operating unit (beside driver seat)

?

Compressed air reservoir

;

Valve block (front axle)

A

Bellows

=

Air suspension filler connection and test connections

B

Valve block (rear axle)



General The chassis can be raised or lowered in order to attach or detach swap bodies or semitrailers.

$

Risk of accident When driving with a raised driving level, there is a risk of damage if you fail to observe the headroom of underpasses.

Do not exceed the maximum permissible vehicle height when driving with a raised driving level. In the Federal Republic of Germany the permissible vehicle height is limited to max. 4 m. In other countries or if the vehicle is operated on international services, comply with all the relevant national regulations. When driving with a lowered driving level, there is a risk of damage due to inadequate spring travel and insufficient ground clearance. The handling and braking behavior of the vehicle may change when dri ving with a level other than the normal level (driving position).


Only drive the vehicle at the normal level (driving position) wherever possible.

+ Vehicles with air-sprung rear axle and steel-sprung front axle: The chassis can only be raised or lowered at the rear axle. Vehicles with full air suspension: The chassis can be raised or lowered at the front and rear axles. If a fault occurs in the Telligent ® level control, this is shown in the display. When the vehicle key in the ignition lock is in the drive position, the height of the chassis readjusts automatically. If the height of the chassis does not readjust automatically, e.g. due to insufficient reservoir pressure, the display shows r. Automatic readjustment is deactivated. If the pressure in the compressed air system is too low:

M Start engine and leave to run.

Operating unit

Risk of injury

$

If the operating unit for the Telligent® level control is not properly inserted into the hold er provided, there is a risk of injury when leaving the cab. You could catch your foot in the connecting cable of the operating unit and trip. For this reason, always insert the operating unit into the holder provided with the connecting cable towards the cab rear wall.


153



:

Operation indicator lamp, raise/lower chassis at front

;

Operation indicator lamp, raise/lower chassis at rear

=

ON/OFF, preselect chassis at front

?

ON/OFF, preselect chassis at rear

A

M1 = Memory, chassis height 1

B

M2 = Memory, chassis height 2

C

Driving position (normal level)

D

Raise

E

Lower

F

STOP (raise/lower)

Raising/lowering the chassis M Apply parking brake. M Turn vehicle key in ignition lock to drive position. M Press button = or ?. The operation indicator lamp : or ; lights up.

M To raise the chassis at the front and rear simultaneously, press buttons = and ?. The operation indicator lamps : and ; light up.

M Press Raise button D or Lower button E. The display shows Ú or Û and the status indicator lights up yellow.

M When the desired height is reached, press STOP button F.

154



Maintaining the level A constant chassis height can be saved for loading and unloading the vehicle.

M Apply parking brake. M Vehicles with leading axle: Lower the leading axle. M If necessary, use the Raise D or Lower E button to set the desired height of the chassis. M Start engine and run until the pressure regulator cuts out. M Press and hold down the STOP button F. M Turn the vehicle key in the ignition lock all the way back. M Release STOP button F. If the reservoir pressure in the compressed air system is sufficient, the stored height of the chassis is kept constant for about 4 to 5 hours.


! Lower the chassis all the way before removing interchangeable flatbeds or containers, otherwise the chassis will rebound violently when the body is removed. This can cause damage to the shock absorbers.

Normal level ! When continuing to drive after changing the chassis height, the chassis must be returned to the driving position (normal level).

M Press normal level button C. The operation indicator lamps go out. The chassis rises or drops to the stored height automatically. When the driving position (normal level) is reached, the display Ú or Ú disappears from the display and the status indicator goes out.


155



Filling the air suspension system from an external source If it is not possible to fill the air suspension system via the tire inflation connection : or the coupling head ;, see page 144, the system can be filled directly via the test connection A. Filling the air suspension system via the test connection A requires a minimum pressure of 8.5 bar. Filling the air suspension system via the tire inflation connection : or coupling head ; requires a minimum pressure of 10 bar. The test connection for the air suspension is located on the left-hand side of the vehicle below the implement carrier.

Test connections If the air suspension control system fails, the test connections =, ? and B can be used to raise/ lower the chassis. Minimum pressure 8.5 bar.

=

Front axle

?

Left rear axle

A

Air suspension supply (external filling)

B

Right rear axle

Raising or lowering the chassis via test connections:

M Turn the vehicle key in the ignition lock all the way back. Raising or lowering the chassis at the front:

M Pressurize or depressurize test connection =. Raising or lowering the chassis at the rear:

M Pressurize or depressurize test connection ? for the left side and/or test connection B for the right side.

! Do not raise the chassis all the way up. The shock absorbers could be damaged.

156


2

Tilting the cab

Tilting the cab Before tilting the cab M Apply parking brake. M Shift transmission to neutral. M Switch off engine. M Switch off auxiliary heater or stationary air conditioner. M If you have to start the engine after tilting the cab, turn the vehicle key in the ignition lock to the drive position.

M Remove all loose objects (e.g. cans, bottles, tools, bags, etc.) from vehicle. M Keep the areas in front of the gearshift lever and in front of the cab clear for safety reasons. M Close all doors and stowage compartments in the cab.


M Close all outside flaps. M Additionally secure the vehicle using wheel chocks to prevent it from rolling. M Check that the coupling pin at the front is correctly inserted. Risk of injury

$

The cab may suddenly drop forward to the end position when it is being tilted. Anybody standing in the tilting range of the cab could be injured. Only tilt the cab when you are certain that nobody is standing in the tilting range. Only stand under the cab when it is in the fully tilted position.

Always tilt the cab all the way forward as far as the end stop. If the tilting hydraulics are defective or leaking, have the system checked at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.


157


Tilting the cab

Vehicles with stationary air conditioner or auxiliary heater M Switch off stationary air conditioner or auxiliary heater.

M Vehicles with liquid gas heater: Disconnect coupling : of gas supply line behind the cab.

M Vehicles with refrigerator: Switch off the refrigerator before tilting the cab and wait 10 minutes after tilting the cab back be fore switching it back on.

1

Vehicles with mechanical/hydraulic cab tilting system

2

1

Actros 1

:

Tilt to driving position

;

Tilt forward

Actros 2/3

Tilting the cab forward:

M Open flap in entryway steps on passenger side and swing up. M Swing valve lever on tilt pump to position :. M Attach pump lever to tilt pump with nut wrench. M Operate tilt pump until the cab is tilted to the end position. The cab is unlocked automatically when the tilt pump is operated. If no resistance can be felt when operating the tilt pump:

M Check that there is sufficient oil in the tilt pump. If firm resistance can be felt when operating the tilt pump:

M Check that the valve lever on the tilt pump is pointing in the desired direction.

158


Tilting the cab

Tilting back to driving position:

$

Risk of accident

Before driving off, make sure that the valve lever is at "Tilt to driving position". Otherwise there is a danger that the cab lock could open by itself while driving and the cab could tip forward if the vehicle brakes.

M Swing valve lever on tilt pump to position ;. M Operate tilt pump until the cab has swung back to the driving position and clicks audibly into the catch. The cab is locked automatically. Do not operate the tilt pump again when the cab is locked.

M Swing down flap in entryway steps on passenger side so that it clicks into place.

$

Risk of accident


If the indicator lamp H fails to go out when the engine is started, the cab is not locked. There is a danger of the cab tipping forward when the vehicle decelerates. Make sure that the indicator lamp H goes out after engine start. If necessary, repeat the lowering procedure and make sure that the cab locks in the driving position.

Vehicles with electrohydraulic cab tilting system Tilting the cab forward Actros 1

Actros 2/3

:

Main electrohydraulic cab tilt system switch

;

Indicator lamp

M Turn vehicle key in ignition lock to drive position. M Press top of main electrohydraulic cab tilt system switch :. The indicator lamp ; in the switch lights up. On road vehicles and construction site vehicles the electrohydraulic cab tilt pump is located in the entryway steps on the passenger side. In car transporters and Low-liner vehicles it is on the right behind the cab.


159


Tilting the cab

Actros 1

Actros 2/3

2

1

3

:

Tilt forward

;

Tilt to driving position

=

Maintenance flap open. Electrohydraulic cab tilt pump switch

M Open flap in entryway steps on passenger side and swing up. M Swing valve lever on electrohydraulic cab tilt pump to position :. M Open maintenance flap. M Actros 2/3: Remove electrohydraulic cab tilt pump switch from bracket. M Press electrohydraulic cab tilt pump switch = and hold down until the cab has tilted to the end position. When the noise of the pump starts to get louder, the cab is at the end position.

160


Tilting the cab

Tilting back to driving position

$

Risk of accident

Before driving off, make sure that the valve lever is at "Tilt to driving position". Otherwise there is a danger that the cab lock could open by itself while driving and the cab could tip forward if the vehicle brakes.

M Move valve lever on electrohydraulic cab tilt pump to position ;. M Swing down flap in entryway steps on passenger side so that it clicks into place. M Press electrohydraulic cab tilt pump switch = and hold down until the cab has tilted to the driving position and is locked. The cab locks automatically.

M Return electrohydraulic cab tilt pump switch = to the bracket under the maintenance flap. M Close maintenance flap.


M Press bottom of main electrohydraulic cab tilt pump switch. M The cab tilting system is switched off. The indicator lamp in the switch goes out. After engine start, the indicator lamp H in the instrument panel goes out.

$

Risk of accident

If the indicator lamp H fails to go out when the engine is started, the cab is not locked. There is a danger of the cab tipping forward when the vehicle decelerates. Make sure that the indicator lamp H goes out after engine start. If necessary, repeat the lowering procedure and make sure that the cab locks in the driving position.

! If some slight pump noise is audible when operating the tilt pump, check that there is sufficient oil in the tilt pump. If a loud pump noise is audible when operating the tilt pump, check whether the valve lever is pointing in the desired direction. If the electrohydraulic cab tilt system fails, check fuse F2 in module A2 in the electrical compartment, see page 162.


161


162

Tilting the cab

Actros 1

Module A1

Fuse F13

Actros 2/3

Module A2

Fuse F2


Engine

Starting and stopping the engine with the cab tilted

$

Risk of injury

When the cab is tilted and the engine is running, make sure that you do not touch hot or moving engine parts (e.g. exhaust manifold, poly-V belt, fan). You may be injured. If working on public roads, pay attention to the traffic situation and secure the area around the vehicle accordingly.

M Turn vehicle key in ignition lock to drive position. 157 . M Tilt cab forwards, see page 157.

Vehicles with 2 pushbuttons on the engine :

Start pushbutton on engine

;

Stop pushbutton on engine


Starting the engine

M Hold down the start pushbutton : until the engine starts.

+ If a gear is engaged, the start pushbutton is inoperative. Increasing the engine rpm

M With the engine running, press the start pushbutton : again and hold it down until the desired engine speed is reached.

+ The engine speed can be increased up to the maximum governed rpm. Switching off the engine

M With the engine running, press the engine stop pushbutton ;. The engine dies. Cranking the engine without starting

M Hold down the start pushbutton : and the stop pushbutton ; at the same time. The engine turns over without starting.


163


Engine

Vehicles with one pushbutton on the engine :

Start/stop pushbutton on engine

Starting the engine Hold down the start/stop pushbutton : until the engine starts.

+ If a gear is engaged, the start pushbutton is inoperative. Starting the engine and increasing the engine rpm

M Press and hold down the start/stop pushbutton :. The engine starts and the rpm increase after about 3 seconds. Hold down the start/stop pushbutton : until the desired engine speed is reached. When the start/stop pushbutton : is released, the engine runs at the set speed.

+ The engine speed can be increased up to the maximum governed rpm. Switching off the engine

M With the engine running, press the start/stop pushbutton : again. The engine dies.

164


Tow-starting General

$

Risk of accident

g n i t r a t s w o T

• If the reservoir pressure in the compressed compressed air system system is too low or nonexistent (warning lamp lights up up below 6.8 bar), there will not be adequate braking effect. The clutch booster and gearshift system may be inoperative depending on the pressure level. • If possible, possible, fill fill the compresse compressed d air system system from an an externa externall source before tow-starting, see page 144 • If the engine engine is not running, only tow-sta tow-start rt the vehicle vehicle on a straight stretch stretch of road (no power steering) steering) • Only Only use use a tow tow bar bar • Risk Risk of skiddin skidding g on wet or slipp slippery ery roads roads • Do not tow-start tow-start in the reversing reversing direction direction with with reverse reverse gear engaged engaged • If spring-loaded spring-loaded brake brake cylinders have have been mechanically mechanically released, released, the parking parking brake is inoperative inoperative • Do not tow-start tow-start if there is engine, engine, transmissio transmission, n, transfer transfer case, axle axle or steering steering damage • Only tow-star tow-startt the vehicle vehicle with with the batteries batteries connect connected. ed.

$

Risk of accident

When tow-starting, the retarder (eddy current b rake) in the vehicle may perform uncontrolled b raking actions. Switch off the retarder before tow-starting. If necessary, use the service brake to brake the vehicle while towstarting.

Preparations for tow-starting ! If the maximum permissible engine speed is exceeded, the warning buzzer sounds. Select a higher movingoff gear or reduce the towing speed. If the display of the Driver Information System (FIS)/onboard computer shows +, reliable gear shifting is not guaranteed.

M Turn vehicle key in ignition lock to drive position. The indicator lamps should light up. If the indicator lamps do not light up, the vehicle cannot be tow-started.

M Deactivate acceleration skid control (ASR). M Switch off Telligent® stability control. M Switch off Active Brake Assist. M In vehicles used to transport hazardous goods, check that the EMERGENCY OFF switches are deactivated, see page 99. 99 .

M Check compressed air supply. The STOP lamp must not light up. In vehicles with Telligent® gearshift system or Telligent® automatic gearshift system if the display shows +, the system must be filled from an external source, see page 144. 144 .


165


Tow-starting M Swing coupling pin cover : up. M Swing coupling jaw cover ; down. M Disengage coupling pin =, swing forward about 90° and pull out upwards.

M Insert tow bar into coupling jaw. M Engage coupling pin = in the catch with an audible click.

Tow-starting vehicles with manual gearshift system (HPS) M Fully depress clutch pedal. M Shift to 5th or 6th gear. M Tow-start vehicle. Do not exceed a towing speed of 20 km/h.

M Slowly release clutch pedal and slowly depress accelerator pedal.

M Immediately after the engine starts: Fully depress clutch pedal and shift transmission to neutral.

Tow-starting vehicles with Telligent ® gearshift system M Fully depress clutch pedal. M Shift to 4th gear. The engaged gear must be shown in the display.

M Tow-start vehicle. Do not exceed a towing speed of 20 km/h.

M Release clutch pedal and slowly depress accelerator pedal.

M Immediately after the engine starts: Fully depress clutch pedal and shift transmission to neutral.

166


Tow-starting Tow-starting vehicles with Telligent ® automatic gearshift system and Mercedes PowerShift


M Shift to 4th gear (16-speed transmission) or 6th gear (12-speed transmission). The engaged gear must be shown in the display.

M Tow-start vehicle. M At about 20 km/h slowly depress accelerator pedal. The electronic system engages the clutch automatically.

M Immediately after the engine starts: Shift transmission to neutral.

+ If the accelerator pedal is operated slowly, the clutch is eased in slowly. If the accelerator pedal is operated quickly, the clutch is let in quickly.


167

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Quick guide General Hazard information ..........................................................................................Page 169 General rules for towing ..................................................................................Page 170 Propeller shaft removal....................................................................................Page 171 Electrical circuits Deactivating acceleration skid control (ASR)/Telligent® stability control (SR) and Active Brake Assist (ABA) ........................................Page 172 Switching transfer case to road position .........................................................Page 173 Air brake system Connecting an external compressed air source...............................................Page 174 Notes on stopped engine, transmission and/or axle damage Stopped engine................................................................................................Page 176 Transmission/transfer case damage ...............................................................Page 176 Front axle damage ...........................................................................................Page 176 Rear axle damage ............................................................................................Page 176 Drive shafts Ascertaining the damage location on a blocked drive train ............................. Page 177 Removing the rear axle drive shafts.................................................................Page 178 Filling planetary gears with oil .........................................................................Page 179 Towing Tow bar............................................................................................................Page 180 Towing in raised position .................................................................................Page 181 Overview of towing options .............................................................................Page 182 Raising by the wheels ......................................................................................Page 183 Raising by the front axle ..................................................................................Page 184 Raising by the front of the frame (Actros 1 only) .............................................Page 184 Raising by the leaf springs (construction site vehicles only) ............................ Page 186 Raising at the rear ...........................................................................................Page 186 Gearshift Engaging the high-speed splitter group on the transmission ........................... Page 189

168


Towing General

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Hazard information

$

Risk of accident

If the vehicle must be transported on a low loader (e.g. after an accident), the maximum permissible vehicle height may be exceeded. Drive with particular care and attention. Observe the maximum headroom of bridges and underpasses. Otherwise you could cause an accident.

$

Risk of accident

If you have your vehicle towed without the engine running, the p ower steering and the compressed air supply are inoperative. It then takes a great deal of effort to steer the vehicle. You could leave the road when cornering or collide with the towing vehicle. When the brake system has no compressed air supply, you can no longer brake the vehicle with the service brake and this could cause you to collide with the towing vehicle. Fill the compressed air system from an external compressed air source. Before starting to tow, talk to the driver of the towing vehicle and agree on clear communication signals. Make sure that you and the driver of the towing vehicle adjust your driving style to suit the more difficult conditions.

$

Risk of accident

When you start to move a vehicle with acceleration skid control (ASR)/Telligent ® stability control (SR) or Active Brake Assist (ABA), the ASR/SR/ABA may perform uncontrollable braking actions. Switch off the ASR/SR/ABA and the ignition before starting to move the vehicle.

$

Risk of accident

When towing with a gear engaged, there is a danger that the engine could start and the vehicle could drive off out of control. Before towing, make sure that the ignition in the vehicle is switched off. Disconnect the batteries if the ignition cannot be switched off or if the batteries are deeply discharged or the cab is inaccessible. You might otherwise cause an accident with possible serious or fatal injury to yourself.

! When towing air-sprung vehicles, check the driving level and correct it if necessary. If the compressed air system cannot be filled, mechanically release the spring-loaded brake cylinder, see page 150. If the vehicle is raised at the rear for towing, all wind guides must be folded in or removed.


169

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Towing General rules for towing • The propeller shafts must be removed to avoid damage to the transmission and transfer case. see page 171 • The safety features for ASR, SR and ABA must be switched off. see page 172 • The transfer case must be switched to road position. see page 173 • The compressed air system must be supplied with sufficient pressure! Make sure that the air suspension is supplied with sufficient compressed air. see page 174 • Wind guides, mirrors and bodies may protrude above and to either side of the vehicle. Pay attention to the height of the vehicle when driving through tunnels and bridges. • Ensure that the vehicle to be towed has an adequate power supply. • Ensure that the vehicle to be towed is adequately lit, if necessary by installing additional lights with turn signals.

170


Towing Propeller shaft removal

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$

Risk of injury

A propeller shaft may fall down and injure you when being removed. Secure the propeller shaft prior to removal to prevent it from falling, e.g. wi th the aid of a second person or by tying up the p ropeller shaft. To avoid damage to the transmission, certain propeller shafts must be removed according to the towing method used.

Model

Tow bar

Raised at front

Raised at rear

4x2

B

B

-

4x4

A and B

B

A

6x2

B

B

-

6x4

B

B

-

6x6

B

B

A

8x4

B

B

-

8x6

A and B

B

-

8x8

A and B

B

-


171

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Towing Electrical circuits Deactivating acceleration skid control (ASR)/Telligent® stability control (SR) and Active Brake Assist (ABA) Actros 1:

:

ASR cutout switch

Actros 2/3:

;

ASR cutout switch

=

SR cutout switch

?

Active Brake Assist OFF switch

A

Active Brake Assist OFF indicator lamp

M Turn vehicle key in ignition lock to drive position. Deactivating acceleration skid control (ASR)

M Press top of ASR shutoff switch : or ;. The indicator lamp d in the instrument panel flashes. Deactivating Telligent ® stability control

M Press top of SR shutoff switch =. The indicator lamp d in the instrument panel flashes. Deactivating Active Brake Assist (ABA)

M Press top of Active Brake Assist OFF switch ?. The Active Brake Assist and the acoustic distance warning are switched off. The indicator lamp A in the switch lights up red. The display briefly shows ABA and Active Brake Assist switched off with a white status indicator.

! The ASR and ABA systems are reactivated automatically when the engine is switched off and restarted.

172


Towing Switching transfer case to road position

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Transfer case switch

1

Road position

2

Neutral position

3

Off-road position

The transfer case may only be shifted when the vehicle is stationary. The neutral position 2 of the transfer case is only necessary when changing from the road position 1 to the off-road position 3.

M Vehicles with Telligent® automatic gearshift system or Mercedes PowerShift: Press mode selector switch M.

M Move transfer case switch to road position 1. The road position is engaged.

! If there is insufficient reservoir pressure, the road position is engaged.


173

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Towing Air brake system Connecting an external source M Open the maintenance flap at the front of the vehicle.

M On vehicles raised at the front for towing: Unscrew connection 21 : on service brake valve. M On vehicles raised at the rear for towing: Unscrew connection 22 ; on service brake valve. Actros 1: Identical adapters are required for both brake circuits (M22x1.5). Actros 2/3: An adapter is required for the front axle brake circuit (M18x1.5). Special tools, see page 196.

! Voss connector: Pay attention to the clip and seal in the stepped hole and do not disassemble the connectors on the Actros 2/3.

M Establish connection between yellow coupling head (brake) of towing vehicle and line from connection 21/22. Special tools, see page 198.

174


Towing M Actros 1: Connect compressed air supply line of

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towing vehicle (red coupling head) to tire inflation connection = or to front coupling head, see page 146, of defective vehicle.

M Actros 2/3: Connect compressed air supply line of towing vehicle (red coupling head) to tire inflation connection = or to front filler connection, see page 146, of defective vehicle. A reservoir pressure of 10 bar is required.

! When filling directly at four-circuit protection valve: Test connection 22 for rear axle brake circuit, test connection 21 for front axle brake circuit. On vehicles with continuous brake systems, note that the brake force at the towed vehicle is relatively low/high depending on the vehicle load and the type of brake system. Install a manual brake force regulator if necessary. A reservoir pressure of 8.5 bar is required. If the spring-loaded actuator of the parking brake cannot be reliably released pneumatically, release it mechanically, see page 150.


175

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Towing Notes on stopped engine, transmission and/or axle damage Stopped engine Comply with section entitled "Towing vehicles with a tow bar", see page 180.

M Remove propeller shaft to drive axles complete, see page 177. M If it is not possible to remove the propeller shaft, remove the appropriate drive shafts, see page 178. M All-wheel drive vehicles: Switch transfer case to road position. M Ensure that the compressed air supply is provided by the towing vehicle. Transmission/transfer case damage Risk of injury

$

A propeller shaft may fall down and injure you when being removed. Secure the propeller shaft prior to removal to prevent it from falling, e.g. with the aid of a second person or by tying up the propeller shaft. Do not turn the vehicle key in the ignition lock to the drive position when the front axle is raised. Otherwise the automatic ASR function may cause uncontrollable braking of the rear wheels may while the vehicle is being towed. This can cause the vehicle to lose lateral stability and break away.

M Remove propeller shafts to drive axles complete, see page 177. Front axle damage Observe the towing instructions as for a stopped engine.

M Raise vehicle at front axle. M Deactivate ASR/SR and ABA, see page 172. M Remove propeller shaft between rear axle and transfer case, see page 177. M On vehicles with air suspension: Set the required chassis height with the operating unit, see page 152. Damage to the rear axle differential M Engage differential lock with bolt, see page 178. M Remove both drive shafts on the damaged axle, see page 178. M On vehicles with two driven rear axles: Remove drive shafts of both rear axles. M Remove propeller shaft from front axle to transfer case, see page 177. Damage to the planetary gear system or the wheel bearings M Raise the damaged axle. M Remove propeller shafts of the axles not raised, see page 177.

176


Towing Drive shafts

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Ascertaining the damage location on a blocked drive train M Secure the vehicle to prevent it from rolling. M Start engine. M Fill compressed air system up to cutoff pressure. M Release parking brake. The indicator lamp ! and the STOP lamp must not light up.

M Disengage the clutch, select a gear and gradually release the clutch pedal.

1

11

10

2

9

3

8

4

5

6

7

Transmission damage :

The engine stalls without propeller shaft ; moving.

Transfer case damage =

Propeller shaft ; moves. Propeller shafts ? and D do not move.

Rear axle damage A, C

The engine/transmission block twists in the frame. In vehicles with transfer case the propeller shafts ;, D and F also move.

Front axle damage E, G

Propeller shafts ;, ? and B move. Propeller shafts D and F do not move.

Wheel bearing/planetary hub reduction drive

The intact wheel turns.


177

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Towing Removing the rear axle drive shafts Engaging differential lock with bolt: M Remove cable connector

: from shift cylinder

housing ;. M Unscrew switch using socket wrench

(size 24 mm). M Carefully screw bolt

= all the way into shift cyl-

inder housing ;. Actros 1 M 18 x 1.5 x 80 mm Actros 2/3 M 22 x 1.5 x 80 mm Special tools, see page 196. M If it is not possible to screw the bolt

= all the

way in: Pull out drive shaft about 150 mm and twist until the bolt = can be screwed fully home.

(example)

(example)

Removing drive shafts on rear axles HL 6 and HL 8: M Turn the vehicle key in the ignition lock all the

way back or remove. M Engage differential lock (interwheel differential

lock) with bolt. M Unscrew bolts

: on wheel hubs.

M Place oil pan under wheel hub. M Collect escaping oil. M Pull out both drive shafts. M Use a cover to protect the wheel hub against dir t.

Special tools, see page 199.

178


Towing Removing drive shafts on rear axles HL 7 and HD 7:

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M Turn the vehicle key in the ignition lock all the way back or remove.

M Engage differential lock (interwheel differential lock) with bolt.

M Unscrew oil drain screws of planetary hub reduction drives.

M Collect escaping oil in an oil pan. M Detach end covers of planetary hub reduction drives =. M Remove retaining rings : using pliers. M Remove both drive shafts together with sun gear. To do this, use special tool ; or a 120 mm long bolt M 8.

M Detach sun gear from drive shaft and reinstall in axle gear.

M Attach end cover =.

Filling planetary gears with oil ! If the towing distance exceeds 100 km, add oil to the planetary hub reduction drives.

M Unscrew oil filler screw in center of end cover =. M Screw oil container ? into end cover =. M Fill planetary hub reduction drive with oil (3.25 l on each side of the wheel). Only use clean transmission oil.

M Unscrew oil container ?. M Screw in oil filler screw and tighten.


179

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Towing Preparations for towing Towing with a tow bar ! Do not tow the vehicle without a compressed air supply. Always use a tow bar for towing. If possible, tow the vehicle empty; unload the vehicle if necessary in order to avoid consequential damage. The coupling jaw may only be loaded to half the permissible gross weight of the tractor vehicle, see page 192. Towing:

M Swing coupling pin cover : up. M Swing coupling jaw cover ; down. M Disengage coupling pin =, swing forward about 90° and pull out upwards. M Insert tow bar into coupling jaw. M Engage coupling pin = in the catch with an audible click. M Run the engine if possible (for power steering, compressed air supply and transmission lubrication). M If the engine cannot be run: Ensure that the compressed air supply is provided by the towing vehicle. On four-axle vehicles with propeller shaft installed, the power steering assistance while driving is supplied by the second power steering pump.

! If the engine is not running, greater effort will be required to steer.

180


Towing Towing in raised position

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! If possible, tow the vehicle empty. Unload the vehicle if necessary in order to avoid consequential damage. On four-axle vehicles it may be necessary to remove the wheels on the second front axle in order to obtain sufficient ground clearance. Secure the brake drums with wheel nuts. If the vehicle is raised, always turn the vehicle key in the ignition lock all the way back and remove. Do not raise the vehicle by the front coupling jaw, by the rear towing coupling or by the rear trailer hitch. Risk of frame damage. Do not raise the vehicle by the frame on one side only. Laden vehicles and empty four-axle vehicles may only be towed when raised at the front by the wheels or axles. Secure the vehicle on the lifting arm of the towing vehicle with suitable fastening materials. Install warning lamps on the vehicle if necessary. Vehicles involved in an accident:

M Before raising the vehicle, check the connections between the frame sections and between the frame and the axle.

M On air-sprung vehicles: Set air suspension (on the raised axle) to "Lower". M If the air spring bellows on a rolling axle are defective, ensure adequate clearance and tow at max. 10 km/h. M Fold up or detach the underride guard if necessary. Additionally for semitrailer tractors with semit railer:

M Make sure there is sufficient clearance between the semitrailer tractor and the semitrailer, particularly when cornering and when starting to drive up steep slopes.

$

Risk of accident Trailer/semitrailer with ABS/EAB:

When towing entire truck/trailer combinations with braked trailer and electronic trailer brake, there is a danger of uncontrolled braking of the trailer/semitrailer. This can cause the trailer/semitrailer to lose lateral stability and break away. Connect the towing vehicle and the trailer/semitrailer with an ABS cable (5-pin). Retrofit an ABS socket on the towing vehicle if necessary. Towing:

M Deactivate acceleration skid control (ASR), Telligent® stability control (SR) and Active Brake Assist (ABA), see page 172.

M Remove the propeller shaft to the rolling axles. M When towing entire combinations, route an ABS cable from the towing vehicle to the trailer/semitrailer (5-pin).


181

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Towing Overview of towing options Vehicle model

182

Raised at the rear by (7)

Raised at the front by Wheels on front axle or front axle housing (5)

Leaf springs

Frame (only Actros 1: vehicles with air suspension on all axles)

Wheels on rear axle or rear axle housing (5)

Wheels on trailing axle

End crossmember (3)

4x2

x

x1

x1, 2, 6

x

x1

4x4

x

x1

x

x1

6x2

x

x1

x1, 2, 6

6 x 2/4

x

x1

x1, 2, 6

6x4

x

6x6

x

8 x 4/4, 8 x 6/4, 8 x 8/4

x2, 4

x1 x1

x1

x1

x1

x1

x1

x1

1

Empty vehicle only

2

Only as far as the nearest unloading station at max. 10 km/h

3

Semitrailer tractor only

4

Remove wheels from 2nd front axle, secure brake drums

5

Make sure suitable axle forks are used (axle diameter and width)

6

See "Air-sprung vehicles" on page 185

7

Additionally secure the steering wheel and remove the roof spoiler

Not permissible

Not permissible


Not permissible

Towing Raising by the wheels

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M Secure vehicle using wheel chocks to prevent it from rolling.

M Set the lift fork ; to the track width of the vehicle.

M Raise the vehicle with the aid of air cushions if necessary. Pay attention to tie rods, soundproofing panels and the level control system on vehicles wi th full air suspension.

M Move the lift fork ; under the vehicle and set to the tire size of the vehicle.

M Raise vehicle. ! Make sure there is sufficient clearance between the arm of the lift fork and the front trim, particularly when cornering and when starting to drive up steep slopes.

M Secure the vehicle with straps : on the wheels and chains on the axles and transfer bar. On vehicles with two front axles:

M Unload vehicle. M Lift the front axle with lifting forks. Ensure that the steering linkage, springs, hoses and cables are not damaged.

M Secure the front axle to the lifting device with chains.

M Make sure that the 2nd front axle has sufficient ground clearance. The 2nd front axle must t ouch the ground while the vehicle is being towed or when cornering; remove the wheels from the 2nd front axle if necessary. Secure brake drums with wheel nuts.

! If the vehicle cannot be unloaded: Tow the vehicle only as far as the nearest unloading station at max. 10 km/h.


183

g n i w o T

Towing Raising by the front axle M Lift the front axle with lifting forks :. Ensure that the steering linkage, springs, stabilizer bars, hoses and cables are not damaged.

M Secure the front axle to the lifting device with chains ;.

If the lifting force of the towing vehicle is insufficient: Tow the vehicle only as far as the nearest unloading station (only possible in the forward direction on a straight, flat road, at max. 10 km/h):

M Raise the vehicle by the 1st front axle, remove wheels and secure brake drums with wheel nuts.

M Detach the drag link on the 2nd front axle. M Lower the vehicle until the 2nd front axle is sharing the load.

Raising by the front of the frame (Actros 1 only) ! Only raise unladen vehicles at the front end of the frame. Actros 2/3: These vehicles must never be raised by the front end of the frame. There is a risk of serious damage to the longitudinal frame members.

184


Towing Air-sprung vehicles

g n i w o T

! Do not raise the vehicle by the front crossmember.

M Fit the support fixture so that it cannot slip out of place.

M Attach the support fixture so that lines, cables, hoses and other detachable parts are not damaged.

M Tie the axle up to the frame using a chain or strap :. Lateral forces arising when a laden vehicle is raised can lead can lead to distortion at the cargo area.

M Set rear axle to driving level. 6 x 2 vehicles: The trailing axle can only be bled if both lines to the air bellows are disconnected and sealed off.

M Secure the vehicle to the lifting device with a chain or straps to prevent it from slipping forward or backward. Leaf-sprung vehicle Never raise the vehicle by the front crossmember.

M Fit the support fixture so that it cannot slip out of place.

M Attach the support fixture so that lines, cables, hoses and other detachable parts are not damaged.

M Tie the axle up to the frame using a chain or strap :. M Secure the vehicle to the lifting device with chains or straps to prevent it from slipping forward or backward. Lateral forces arising when a laden vehicle is raised rais ed can lead to distortion at the cargo area.


185

g n i w o T

Towing Raising by the leaf springs s prings (construction site vehicles only) ! In certain vehicles a crossmember may be installed under the spring mounting. The spring support cannot be used on these vehicles. Only unladen vehicles should be raised by the leaf springs, using a jointed spring support.

M Install jointed spring support : in the support fixture or lifting device and secure.

M Fasten lifting device with spring support : to leaf spring and secure.

M Secure the vehicle with a chain hoist ; to prevent it from slipping.

Raising at the rear M On vehicles with driven front axle: Remove propeller shaft between transfer case and front axle complete; mark the propeller shaft before removing.

M Remove the vehicle key from the ignition lock and engage the steering wheel lock.

M Secure the steering wheel with two additional straps : in the tangential direction to prevent it from turning.

M Make sure there is sufficient clearance of the front cab trim (front spoiler).

M Detach wind guides.

186


Towing Raising by the rear wheels

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M Set the lift fork to the track width of the vehicle. M Move the lift fork under the vehicle and set to the tire size.

M Raise the vehicle and secure at the wheels with straps and at the axle with chains.

Raising the vehicle at the lift axle It is only permissible to raise the vehicle at the lift axle when the vehicle is unladen, i.e. without superstructure or swap body. On semi-laden vehicles, place a square wooden block between the longitudinal frame member and the lift axle.

M Secure the vehicle to the lifting device with chains. Attach the chains so that lines, cables, hoses and other detachable parts are not damaged.

M Before raising, tie the 1st rear axle to the frame with chains, see page 188. 188 .

! Observe the tire pressure and changes in the tire temperature. The front axle load increases when multi-axle vehicles are raised at the last axle.


187

g n i w o T

Towing Raising vehicles with two drive axles at the rear Laden four-axle vehicles must not be raised at the rear. When raising unladen vehicles, remove the wheels on the 2nd front axle (secure the brake drums with wheel nuts). Otherwise there is a danger of frame damage when cornering.

M Place hard wood blocks 100 x 100 x 500 mm between the axle housing and frame on both sides and secure to prevent them from slipping.

M Set the lift fork to the track width and tire size. Raise the vehicle and secure to the lifting device with chains.

Raising the vehicle at the rear crossmember (semitrailer tractors only)

M If necessary, detach the trailer hitch or towing coupling.

M Unfasten the wiring harness in the crossmember and the compressed air reservoir if necessary and move out of the way.

! Actros 2/3: Raising the vehicle by the end of the frame can lead to frame damage, so only raise by the wheels or the axle housings.

M Tie the axle up to the frame with chains. Place a wooden block between the frame and the chain.

M Attach lifting device. M Secure the vehicle to the lifting device with straps.

188


Towing Gearshift

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Engaging the high-speed splitter group on the transmission On vehicles with manual gearshift or Actros 1 with Telligent® gearshift/Telligent® automatic gearshift system, the high-speed group can be engaged.

M Shift transmission to neutral. M Unscrew stop plug : on transmission housing (above the propeller shaft).

M Screw "GP" adjusting screw ; (vehicle document wallet) all the way in and tighten.

1

Special tools, see page 196.

! On vehicles with a TELMA transmission, it is not possible to shift the high-speed splitter groups on the transmission.

GP

2


189

y r e v o c e R

Recovery General ! The force application points referred to in these guidelines do not have an infinite load capacity. They should only be regarded as suitable points for the application of external forces and are intended for experienced recovery experts. Application of these instructions is left to the discretion of the recovery experts. The steering may be damaged if the vehicle is towed with recovery tools which are fastened to the wheels/ hubs on steering axles.

Force application points • To avoid concentrating the frame load at single points, the connecting points between the longitudinal frame members and the frame crossmembers are most suitable. The straps used should be as wide as possible so as not to damage any detachable frame parts, lines, cables and hoses. • Use as many force application points as possible. • One-sided pulling will cause distortion or cracking of the frame. • The towing straps should form an isosceles triangle with the smallest possible angle. • Load compensating rollers should be used to ensure that the pulling force is equal on both sides. • Avoid towing at an angle wherever possible. A towing angle of max. 15° to the longitudinal axis of the vehicle must not be exceeded. • The utmost care is to be exercised when applying external forces to the axles and axle connecting components.

Before recovering M Always unload the vehicle first, especially vehicles with box bodies. This reduces the towing forces required. Further damage to the vehicle can be reduced to a minimum.

M If it is not possible to unload the vehicle, choose as many force application points as possible. Straightening the vehicle M Apply parking brake. M Use as many force application points as possible or apply the forces in the vi cinity of frame crossmembers. Use straps.

M If possible, assist the procedure using inflatable jacks. M The forces can be distributed evenly by using guide pulleys or load compensation rollers. After straightening ! Do not start the engine. Oil residues in the intake system can cause the engine to overrev, which may result in engine damage.

190


Recovery Super-wide tires

y r e v o c e R

Converting from super-wide tires to twin tires If it is not possible to continue driving with a damaged super-wide tire, it can be replaced on one side with twin tires of size 315/70 R 22.5.

! With these tires the vehicle may be driven for 50 km at max. 62 km/h.

Risk of accident

$

Exceeding the specified tire load capacity or the permissible tire maximum speed can lead to ti re damage or tire failure. This could cause you to lose control of the vehicle and cause an accident with possible injury to yourself and others. For this reason, only use the tire makes, rim sizes and tire sizes approved for your vehicle model and pay attention to the tire load capacity and speed index necessary for your vehicle. To avoid damage to the super-wide tires, they are equipped with a specially tailored run flat system. For this reason only approved super-wide tires and run flat systems may be used. Never operate the super-wide tires without the run flat system. If a super-wide tire fails, you could lose control of the vehicle and cause an accident with possible injury to yourself and others.


191

y r e v o c e R

Recovery Maximum permissible pulling forces ! Recovery at the front coupling jaw Actros 1: • 10 t (2 axles), 20 t (3 and 4 axles). Actros 2/3: • 20 t (2, 3 and 4 axles) • Towing angle max. 15°.

! Recover semitrailer tractors fitted with weightoptimized end crossmember at the towing coupling with a force of max. 6 t. Observe the data on the model plate of the towing coupling.

! Recovery at the trailer hitch • Pin diameter 38 mm: max. 12 t pulling force • Pin diameter 48 mm: max. 20 t pulling force

192


Recovery Recovering the vehicle from the rear

y r e v o c e R

Recovering by the frame Only for vehicles without integral rear end and vehicles which are not sunken in the ground.

M Remove towing coupling and/or compressed air reservoir.

M Unfasten wiring harness in crossmember if necessary and place to one side.

M To prevent pinpoint frame loads insert a suitable wooden block (see Special tools, Page 196). The block must overlap the end crossmember.

Recovering by the axle (sunken vehicles) M Attach towing straps to axle housing.


193

y r e v o c e R

194

Recovery M Fit the straps : so that detachable parts, stabilizer bars, hoses and cables are not damaged.


Recovery Safety components

y r e v o c e R

When recovering a vehicle, pay attention to the following safety components:

Frame • Longitudinal members and crossmembers.

Cab • Cab mounting including catch.

Steering system • Steering shaft, steering wheel with ignition lock, steering gear, steering gear pitman arms, pitman arms, track levers, steering cylinders, drag links, tie rods and joints. • Mounting of the steering gear on the frame.

Front axle(s) • Front axle housing and attaching parts for suspension and brakes, kingpins, steering knuckles.

Rear axle(s) • Rear axle housing and attaching parts for suspension and brakes.

Axle joints • Springs, spring shackles, spring bracket. • Air spring bellows, detachable parts of air spring bellows. • Wishbone control arm, longitudinal and transverse control arms, stabilizer bars, including attaching parts.

Wheels • Wheel hub, tires, rims, wheel mounting parts.

Brakes • All mechanical, hydraulic, pneumatic and electrical actuating systems and brake force transmission mechanisms. • Brake drums, disks and calipers.

Propeller shafts Vehicle connecting parts • Fifth wheel couplings and articulation journals, trailer hitches and towing couplings at front and rear with installations.

Electrical system • Wiring harnesses and electrical lines.


195

e s l o o t l a i c e p S

Special tools Mercedes-Benz special tools The special tools listed on this page can be found in the vehicle document wallet in Actros vehicles. The special tools can also be acquired from any Mercedes-Benz service center. Designation

Actros 1

Actros 2/3

Adapter for transmission shift shaft

Emergency shift at transmission, see page 126


Order number: A 945 268 05 71 Adjusting screw for 3rd and 4th gears

3/4

Order number: A 945 268 02 71 Adjusting screw for reverse gear

R



Order number: A 945 268 03 71

Adjusting screw for high-speed splitter group

GP

196

Order number: A 945 268 01 43


Vehicles with manual gearshift system (HPS) only

Special tools The following special tools/aids can be acquired from any Mercedes-Benz service center. Special tools and bolts are not included in the vehicle tool kit.

Special tools


(For extracting the drive shafts on axles with planetary hub reduction dri ve, see page 178).

Bolts Bolt M 8 x 120 mm (For extracting the drive shafts on axles with planetary hub reduction drive, see page 178). Bolt M 18 x 1.5 x 80 mm (For locking the rear axle differential, see page 178). Bolt M 22 x 1.5 x 80 mm (For locking the rear axle differential, see page 178).

Adapter for compressed air connection : M 18x1.5 part no. A 000 431 29 31 ; M 22x1.5 part no. A 004 997 82 72 Adapter for test connections M 18 part no. A 000 431 29 31 M 22 part no. A 000 431 30 31

Pressure booster : for vehicles with brake system operating pressure of 8.5 bar

1


197


Special tools Compressed air hose ;

Connection

=

Hose

?

Adapter

A

Coupling head

2

3

5 4

Lifting fork B

Front axle lifting fork

C

Spacer plate

6

7

198


Special tools Shop-made special tools Square wooden block for rear crossmember.

50 0 mm

Wheel hub cover


m m 0 6 1

mm 150

1

Item

Designation

Dimension

:

Diameter

230 mm

;

Hole circle radius

95 mm

=

Hole diameter

19 mm

?

Undercut depth

5 mm

A

Undercut diameter

150 mm

2

5

4

3 N54.10-2211- 00

i The undercut is necessary because of the protruding axle tube, otherwise the cover will not lie flat.

The following special tools/aids are recommended by Mercedes-Benz. Inflatable jack Lift height up to 200 mm, lift force up to 9000 kg


199

Index A ABA (Active Brake Assist) 140 System abbreviations 65

Brake system, Nordic countries 140 BS, see System abbreviations Actros 1 (as of 01/2000) 40 Actros 1 (up to 12/1999) 19 Actros 2/3 (as of 01/2003) 65

ABS, see System abbreviations Actros 1 (up to 12/1999) 19 Actros 1 (as of 01/2000) 40 Actros 2/3 (as of 01/2003) 65

BTS, see System abbreviations 65

Active Brake Assist 140

EAB, see System abbreviations Actros 1 (up to 12/1999) 19 Actros 1 (as of 01/2000) 40 Actros 2/3 (as of 01/2003) 65

EDW, see System abbreviations Actros 1 (up to 12/1999) 19 Actros 1 (as of 01/2000) 40 Actros 2/3 (as of 01/2003) 65

AdBlue® level gauge 55

C

AdBlue® tank 94

Chassis frame 154, 156

Electrical system 98

Additional tank 93

Chassis number 10

Adjusting screw 189

Clutch operating system 123

Electronic Air-Processing Unit (EAPU) 136

AG, see System abbreviations

Combination tank 94

Actros 1 (as of 01/2000) 40 Actros 1 (up to 12/1999) 19 Actros 2/3 (as of 01/2003) 65

Compressed air production 134 Compressed air system Filling from an external source 144 Versions 134

AGE, see System abbreviations 19 AHE, see System abbreviations 19 Aids 197, 199

Constant pressure system with Electronic Air-Processing Unit (EAPU) 136 with separate four-circuit protection valve 135

Air suspension system 152 Antilock brake system 19, 40, 65 Anti-theft alarm system 19 APU, see System abbreviations 65

Conventions 9

ART, see System abbreviations

Coupling jaw 166, 180, 192

Actros 1 (as of 01/2000) 40 Actros 2/3 (as of 01/2003) 65

Automatic gearshift system 113

Coupling pin 166 Crossmember 185, 188

D

Axle configuration 11

Detachable frame parts 190

Axle housing 193

Differential lock 178

Battery tray 107 Disconnecting and connecting 106 Removing/installing 107

Battery terminals 106 Bellows 152 Bleed screw 97 Bleeding 97 Bleeding the fuel system 96 Blocked drive train 177 Brake control 19 Brake pressure limiting 47 Brake system 138

Electronic trailer/semitrailer brake 19 EMERGENCY OFF switch 99 RESET switch 101

Emergency shift at transmission 126 Emergency shift, transmission 120 Telligent® automatic gearshift system 124 ® Telligent automatic gearshift system (Actros 1) 123 ® Telligent gearshift system 124 Telligent® gearshift system (Actros 1) 123

Engine oil pressure

Display

Batteries

Electronic system malfunction display 26

Engine diagnosis 85

Auxiliary heater 21, 158

B

200

E

Actros 1 (up to 12/1999) 17 Actros 2/3 (as of 01/2003) 57

Display messages Actros 1 (as of 01/2000) 43 Actros 1 (up to 12/1999) 22 Actros 2/3 66

Displays Actros 1 (as of 01/2000) 29–34 Actros 1 (up to 12/1999) 16–18 Actros 2/3 (as of 01/2003) 52– 55

Drive control 20 Drive shafts 177 Drive train 177 Driver Information System 31

i Guidelines for Breakdown Services

Actros 1 (as of 01/2000) 90 Actros 1 (up to 12/1999) 89

Engine, starting and stopping with the cab tilted 163 EPB, see System abbreviations 19 EPS, see System abbreviations 20 Event code 36 Export vehicles 101 External force application 190 External force application points 190

Index F

GM, see System abbreviations 65

K

FFB, see System abbreviations

Ground cable 103

KB, see System abbreviations

Actros 1 (up to 12/1999) 19 Actros 1 (as of 01/2000) 40

Filler connection 152

GS back-up mode 128 GS, see System abbreviations

Filler neck

Actros 1 (up to 12/1999) 20 Actros 1 (as of 01/2000) 41 Actros 2/3 (as of 01/2003) 65

Diesel fuel 94 Hydraulic fluid 94

Filling from an external source Air suspension system 156 Brake system 144

Actros 1 (up to 12/1999) 20 Actros 2/3 (as of 01/2003) 65

Ground clearance 183

Guide pulleys 190

Flame starting system 20 FM, see System abbreviations 65 FMR, see System abbreviations 20

KS, see System abbreviations Actros 1 (up to 12/1999) 20 Actros 1 (as of 01/2000) 41 Actros 2/3 (as of 01/2003) 65

Trade association 9 Vehicle ownership 9

KSA, see System abbreviations

FIS 31 Actros 1 (up to 12/1999) 20 Actros 1 (as of 01/2000) 40 Actros 2/3 (as of 01/2003) 65


Guidelines

Filling pressure 144 FLA, see System abbreviations

KOM, see System abbreviations


H Half-gear switch 111, 113 Hand pump 95, 97 Hazardous goods vehicles 99

L

HM, see System abbreviations 65

Level control 152

HPS, see System abbreviations

Level gauge AdBlue® 55 Fuel 55


Folding out clutch pedal 123 Force application points 190

Hydraulic fluid 94

Lift axle 187

FR, see System abbreviations

Hydraulic-pneumatic power shift 110

Lift fork 183, 188

HZR, see System abbreviations

Lifting forks 183, 184


Lifting device 183


Frame crossmember 190 Frame distortion 190 Frame load 190, 193

I

Front axle 183

Indicator lamps

Main tank 93

Actros 1 (as of 01/2000) 49 Actros 1 (up to 12/1999) 27 Actros 2/3 (as of 01/2003) 84

Fuel level sensor 93 Fuel prefilter 95

Inflatable jacks 190

Fuel reserve indicator 55

INS, see System abbreviations

Fuel tank 93


Fuel reserve indicator 55

Function button, shift control unit 111, 113

Instrument panel Actros 1 (up to 12/1999) 15 Actros 1 (as of 01/2000) 28 Actros 2/3 (as of 01/2003) 50

G Gas supply line, auxiliary heater 158 Gate cylinder 120 Gear cylinder 120 Gearshift 109

Longitudinal frame member 190

M

Frequent-stop brake 139 Front coupling head 146

Liquid gas heater 158

Integral rear end 106 Interwheel differential lock 178

J Jump starting 102

Malfunction classes 26, 36 Manual gearshift system (HPS) 110 Menu overview Actros 1 (as of 01/2000) 33 Actros 2/3 (as of 01/2003) 58

Mercedes PowerShift 113 Mode Automatic 114 Manual 114

Mode selector button 114 Mode selector switch 114 Model plate 10 MR, see System abbreviations Actros 1 (up to 12/1999) 20 Actros 1 (as of 01/2000) 41 Actros 2/3 (as of 01/2003) 65

MSF, see System abbreviations 65

Jumper cables 102 Jump-start connection point 103

Guidelines for Breakdown Services i

201

Index N

Steering linkage 183

Negative terminal 106

Recovery and towing company association 9

Neutral button 111, 113

Recovery experts 190

STOP lamp

Neutral position 112, 115

Refrigerator 158

NR, see System abbreviations

Reservoir pressures 137

Stop pushbutton 163

RESET switch 101

Straps 190

RET, see System abbreviations 21

Super-wide tires 191

Reverse gear 112, 115

Switching


Actros 2/3 (as of 01/2003) 64

Acceleration skid control 172 Stability control 172 Transfer case 173

RS, see System abbreviations

O


Oil level in engine Actros 1 (as of 01/2000) 90 Actros 1(bis 12/1999) 89 Actros 2/3 (as of 01/2003) 91

Onboard computer 56 Overview Batteries 98 Electrical system 98

Overview of fuel system 92

P

S Safety components 195

T

Safety valve 140

TCO, see System abbreviations

Shift control unit 111, 113 Shift shaft 126 SIL, see System abbreviations

Parking brake 148 Permissible pulling forces 192 PLD, see System abbreviations 20 Positive terminal 106 PowerShift 113 Prefilter 95 Pressure regulating system 135

System abbreviations Actros 2/3 (as of 01/2003) 65

Shock absorbers 156 Actros 1 (up to 12/1999) 21 Actros 1 (as of 01/2000) 42

SIR, see System abbreviations Actros 1 (up to 12/1999) 21 Actros 1 (as of 01/2000) 42

SPA, see System abbreviations Actros 1 (as of 01/2000) 42 Actros 2/3 (as of 01/2003) 65


Teach-in process 116 TEL, see System abbreviations 65 Telligent® automatic gearshift system 113 Telligent® brake system 138 Telligent® gearshift system 111 Telligent® level control Normal level 154 Operating unit 153

Telligent® level control 152

Pressure table 137

Special tools 196, 197

Test connection 148, 156

PSM, see System abbreviations

Splitter group 110

Tilt pump 158

Spring-loaded actuator

Tilting the cab 157


Parking brake, releasing 148 Safety valve 140

Pump lever 158

Springs 183

Pump noise 161

SRS, see System abbreviations

Q Quick charger 102


Tire inflation connection 147 TMB, see System abbreviations 65 TMF, see System abbreviations 65 Tow bar 166, 180 Towing 168 Towing angle 190

Stabilizer bars 184, 194

Towing forces 192

Start pushbutton 163

Towing straps 190

R

Start/stop pushbutton 164

Tow-starting 165

RAD, see System abbreviations 65

Starting off 112, 115

Tow-starting speed 166

Radio remote control 19

Stationary air conditioner 158

TP, see System abbreviations 65

Range group 110

Status indicator

Track width 188

Quick guide 12

Recovery 190

202

Steering wheel lock 186


i Guidelines for Breakdown Services

Trailer coupling 192 Trailer recognition module 19

Index V

W

Z

Valve block 152

Warning buzzer 86

ZDS, see System abbreviations 65

Vehicle

Water separator 95

ZHE, see System abbreviations

Identification number 11 Leaf-sprung 185 Model designation 10 Raising at the frame 184 Raising at the rear crossmember 188 Raising by the leaf springs 186 Raising by the wheels 187 Straightening 190

Vehicle Diagnostic System (FDS) 16 Vehicle model designation 11 Vehicle model plate 10 Vehicle Service System (FSS) 16


Water/fuel mixture 97 Wheel bearing damage 177 Wheel hubs 178

ZL, see System abbreviations 65

Wooden block 193, 199 WR, see System abbreviations 65

ZV, see System abbreviations 42

WS, see System abbreviations Actros 1 (up to 12/1999) 21 Actros 1 (as of 01/2000) 42 Actros 2/3 (as of 01/2003) 65

WSK, see System abbreviations Actros 1 (up to 12/1999) 21 Actros 1 (as of 01/2000) 42 Actros 2/3 (as of 01/2003) 65

Vehicle tool kit 197 Vehicle version 11 Vent line 93

Guidelines for Breakdown Services i

203

actros.pdf

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