Towing - Recovery Actros

Transcription

1 Towing - Recovery Actros

2

3 Service Towing Recovery Actros Guidelines for Breakdown Services 2009 Edition Daimler AG Teile-Technik und Technische Information (GSP/OI) D Stuttgart

4 Information and copyright

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

6 Information and copyright Technical details of the data and illustrations provided 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: Fax: +49-(0) 18 05/ or Address: Daimler AG GSP/OI HPC R822, W002 D Stuttgart Technical status: 11/ 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.

7 Contents General Safety and liability information 9 Conventions 9 Vehicle identification 10 Description and roadside assistance Quick guide 12 Instrument panel Actros 1 (up to 12/1999) 15 Overview 15 Vehicle Diagnostic System/Vehicle Service System 16 Note on display messages 17 STOP lamp 18 System abbreviations 19 Display messages 22 Indicator lamps 27 Instrument panel Actros 1 (as of 01/2000) 28 Overview 28 Driver Information System (FIS) 31 Note on display messages 35 STOP lamp 39 System abbreviations 40 Display messages 43 Indicator lamps 49 Instrument panel Actros 2/3 (as of 01/2003) 50 Overview: Actros 2 50 Overview: Actros 3 51 Onboard computer 56 Note on display messages 62 STOP lamp 64 System abbreviations 65 Display messages 66 Indicator lamps 84 Warning buzzer 86 Guidelines for Breakdown Services (Subject to technical modifications) i 5

8 Contents Oil level in engine 89 Actros 1 89 Actros 2/3 91 Fuel system 92 Overview of fuel system 92 Hand pump (location) 95 Bleeding the fuel system 96 Electrical system 98 EMERGENCY OFF switch 99 Jump starting 102 Batteries 105 Gearshift 109 Manual gearshift system 110 Telligent gearshift system 111 Telligent automatic gearshift system and Mercedes PowerShift 113 Teach-in process (Telligent gearshift/automatic gearshift system) 116 Teach-in errors 119 Emergency shift of manual gearshift system 120 Actros 1: Emergency shift of Telligent gearshift system and Telligent automatic gearshift system 123 Actros 2/3: Emergency shift of Telligent gearshift system, Telligent automatic gearshift system or Mercedes PowerShift 128 Compressed air production 134 Versions 134 Pressure regulating system 135 Constant pressure system with separate four-circuit protection valve 135 Constant pressure system with Electronic Air-Processing Unit (EAPU) 136 Pressure table 137 Brake system 138 General 138 Telligent brake system 138 Frequent-stop brake 139 Safety valve 140 Active Brake Assist (ABA) 140 Location of components 143 Filling the brake system from an external source 144 Releasing the spring-loaded parking brake i Guidelines for Breakdown Services (Subject to technical modifications)

9 Contents Telligent level control 152 Diagram of Telligent level control 152 Raising/lowering the chassis frame 154 Filling the air suspension system from an external source 156 Tilting the cab 157 Engine 163 Starting/stopping the engine with the cab tilted 163 Tow-starting Tow-starting 165 General 165 Preparations for tow-starting 165 Tow-starting vehicles with manual gearshift system 166 Tow-starting vehicles with Telligent gearshift system 166 Tow-starting vehicles with Telligent automatic gearshift system and Mercedes PowerShift 167 Towing Quick guide 168 Towing 169 General 169 Electrical circuits 172 Air brake system 174 Stopped engine, transmission and/or axle damage 176 Drive and propeller shafts 177 Towing with a tow bar 180 Towing in raised position 181 Raising by the wheels 183 Raising by the front axle 184 Raising by the front of the frame (Actros 1 only) 184 Raising by the leaf springs (construction site vehicles only) 186 Raising at the rear 186 Gearshift 189 Guidelines for Breakdown Services (Subject to technical modifications) i 7

10 Contents Recovery Recovery 190 General 190 Super-wide tires 191 Recovering the vehicle from the rear 193 Safety components 195 Special tools Special tools i Guidelines for Breakdown Services (Subject to technical modifications)

11 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. 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 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. 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 directly 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 Guidelines for Breakdown Services (Subject to technical modifications) i 9General

12 General Vehicle identification Vehicle model designation Permissible gross vehicle weight in tonnes 44 Engine output in hp (x 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 Vehicle model Headlamp basic setting Smoke index Rear axle ratio Vehicle identification number (VIN) Permissible gross vehicle weight Permissible axle loads (example) 10 i Guidelines for Breakdown Services (Subject to technical modifications)

13 Key to vehicle identification number Vehicle identification General Vehicle identification number (VIN) WDB L WDB Vehicle manufacturer 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 Vehicle identification end number Vehicle version (model designation code) 930/950 = Platform vehicle 932/952 = Dumper 933/953 = Concrete mixer 934/954 = Semitrailer tractor.04 Axle configuration x 2 07, 08 4 x x 2 DNA (dual-tired trailing axle, Nummek) 20, 21 6 x x 2/2 (Hendrickson leading axle, Great Britain only) 22 6 x 2/4 14, 16, 24 6 x 4 18, 41 6 x 6 30, 31, 42 8 x 4/ x 6/ x 8/4 8 x 8/4 8 Number of wheels or wheel pairs x 8 Number of driven wheels or wheel pairs /4 Number of steered wheels Model designations Model designations Actros 1 up to manufacture year 12/2002 Actros 2/3 as of manufacture year 01/2003 Guidelines for Breakdown Services (Subject to technical modifications) i 11

14 Description and roadside assistance Quick guide Instrument panel, Actros 1 (up to 12/1999) Overview... Page 15 Vehicle Diagnostic System (FDS)/Vehicle Service System (FSS)... Page 16 Note on display messages... Page 17 STOP lamp... Page 18 System abbreviations... Page 19 Display messages... Page 22 Electronic system malfunction displays... Page 26 Indicator lamps... Page 27 Instrument panel Actros 1 (as of 01/2000) Overview... Page 28 Reservoir pressure gauge for brake circuits 1 and 2... Page 29 Gear indicator... Page 30 Fuel level indicator... Page 30 Driver Information System... Page 31 Note on display messages... Page 35 STOP lamp... Page 39 System abbreviations... Page 40 Display messages... Page 43 Indicator lamps... Page 49 Instrument panel, Actros 2/3 (as of 01/2003) Overview: Actros 2... Page 50 Overview: Actros 3... Page 51 Reservoir pressure gauge for brake circuit 1 or 2... Page 52 Gear indicator... Page 53 Fuel/AdBlue level gauge... Page 55 Onboard computer... Page 56 Note on display messages... Page 62 STOP lamp... Page 64 System abbreviations... Page 65 Display messages... Page 66 Indicator lamps... Page 84 Warning buzzer Warning buzzer... Page i Guidelines for Breakdown Services (Subject to technical modifications)

15 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... Page 92 Fuel tank... Page 93 Hand pump location... Page 95 Bleeding the fuel system... Page 96 Electrical system Overview of electrical system... Page 98 EMERGENCY OFF switch... Page 99 Jump starting... Page 102 Batteries... Page 105 Gearshift Overview of gearshift... Page 109 Manual gearshift system... Page 110 Telligent gearshift system... Page 111 Telligent automatic gearshift system and Mercedes PowerShift... Page 113 Teach-in process... Page 116 Teach-in errors... Page 119 Emergency shift of manual transmission (HPS)... Page 120 Emergency shift of Telligent gearshift system and Telligent automatic gearshift system (Actros 1)... Page 123 Emergency shift of Telligent gearshift system, Telligent automatic gearshift system and Mercedes PowerShift (Actros 2/3)... Page 128 Compressed air production Versions... Page 134 Pressure regulating system... Page 135 Constant pressure system with separate four-circuit protection valve... Page 135 Constant pressure system with Electronic Air-Processing Unit (EAPU)... Page 136 Pressure table... Page 137 Quick guide Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 13

16 Description and roadside assistance Quick guide Brake system General... Page 138 Frequent-stop brake... Page 139 Safety valve... Page 140 Active Brake Assist... Page 140 Location of components... Page 143 Filling the brake system from an external source... Page 144 Releasing the spring-loaded parking brake... Page 148 Telligent level control system Diagram of Telligent level control system... Page 152 General... Page 153 Operating unit... Page 153 Raising/lowering the chassis... Page 154 Filling the air suspension system from an external source... Page 156 Tilting the cab Before tilting... Page 157 Mechanical/hydraulic... Page 158 Electrohydraulic... Page 159 Engine Starting and stopping the engine with the cab tilted... Page i Guidelines for Breakdown Services (Subject to technical modifications)

17 Overview Instrument panel Actros 1 (up to 12/1999) Description and roadside assistance : 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. = The right-hand field of the display see page 16 shows operating information. 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. H Chassis display Starting-off aid Differential lock(s) Trailing axle Power take-off(s).? Indicator lamps, see page 27 I Gear indicator display A Level control display Vehicles with Telligent gearshift system, see B Coolant temperature gauge page 111, or Telligent automatic gearshift system, see page 113. C Fuel level gauge D Engine oil pressure gauge E Reservoir pressure, brake circuit 1 J Auxiliary heater timer F Reservoir pressure, brake circuit 2 K Tachograph Guidelines for Breakdown Services (Subject to technical modifications) i 15

18 Description and roadside assistance 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 displayed language is saved automatically. M Press the "QUIT" button to hide the display. 16 i Guidelines for Breakdown Services (Subject to technical modifications)

19 Note on display messages Left display field : yellow/red 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. Instrument panel Actros 1 (up to 12/1999) 1 2 Description and roadside assistance Display messages with code, see page : Fault code Electronic system failure, see page 19. MR: Engine control Guidelines for Breakdown Services (Subject to technical modifications) i 17

20 Description and roadside assistance 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 absolutely 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. Oil level OK: Tow the vehicle away. The STOP lamp : lights up and the warning "Brake system reservoir pressure" is displayed: Cause Action Page Reservoir pressure of brake circuit 1 or 2 below 6.8 bar. Fill compressed air system from an external source. Tow the vehicle away Reservoir pressure of brake circuit 3 below 5.5 bar. Fill compressed air system from an external source, or release spring-loaded parking brake mechanically Tow the vehicle away i Guidelines for Breakdown Services (Subject to technical modifications)

21 System abbreviations If an electronic system fails, only the abbreviation : of the defective electronic system is displayed. 1 Instrument panel Actros 1 (up to 12/1999) 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. Description and roadside assistance Abbreviation Description Action ABS Antilock brake system: AG (AGE) AHE BS (EPB) EAB The wheels may lock up when braking. The lateral stability of the vehicle may change. Automatic gear selection (Vehicles with Telligent automatic gearshift system) Trailer recognition module: The braking behavior of the vehicle may change. 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. 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. M Drive with special care or tow the vehicle away, see page 153. M Fold out the clutch pedal and shift gears manually, see page 123. M Drive with special care. M Drive with special care. M Drive with special care. M Drive with special care. EDW Anti-theft alarm system M Have the system repaired. FFB Radio remote control M Lock/unlock the doors with the vehicle key. Guidelines for Breakdown Services (Subject to technical modifications) i 19

22 Description and roadside assistance Instrument panel Actros 1 (up to 12/1999) Abbreviation Description Action FLA Flame starting system (cold-starting aid): M Have the system repaired. 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 M Have the system repaired. INS KB Instrument cluster: Important information (warnings, malfunctions) can no longer be displayed. Clutch operating system (Vehicles with Telligent automatic gearshift system) M Drive with special care. M Tow the vehicle away if necessary, see page 169. M Fold out the clutch pedal and shift gears manually, see page 123. KOM Communications interface M Have the system repaired. KS Clutch control M Drive with special care. (Vehicles with Telligent automatic gearshift system) M Fold out the clutch pedal and shift gears manually, see page 123. KSA Comfort locking system M Have the system repaired. MR (PLD) Engine control: The accelerator pedal is inoperative and the engine speed is constantly below 1300 rpm. (Vehicles with Telligent automatic gearshift system) 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 i Guidelines for Breakdown Services (Subject to technical modifications)

23 Abbreviation Description Action NR PSM Level control: The handling of the vehicle may change (e.g. chassis leans to one side, center of gravity changed). Parameterizable special module: The power take-off is inoperative. Instrument panel Actros 1 (up to 12/1999) M Drive with special care. M Have the system repaired. RS (RET) Retarder control M Drive with special care. SIL Seat electronics, left M Have the system repaired. SIR Seat electronics, right M Have the system repaired. SRS Supplemental restraint system M Have the system repaired. WS Maintenance system M Have the system repaired. WSK Torque converter clutch: The handling of the vehicle may change. M Tow the vehicle away, see page 169. ZHE Auxiliary heater M Have the system repaired. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 21

24 Description and roadside assistance Instrument panel Actros 1 (up to 12/1999) Display messages Display messages on a yellow background Display message Possible cause/ consequence Risk of accident $ The poly-v belt has snapped or the three-phase 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. 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. Possible remedy M Stop the vehicle as soon as possible taking into account the traffic situation. M Switch off engine and apply parking brake. 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 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. 22 i Guidelines for Breakdown Services (Subject to technical modifications)

25 Display messages on a red background Display message Possible cause/ consequence Risk of accident $ The poly-v belt has snapped or the three-phase 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. The engine oil level has dropped about 2 l below the minimum fill level. 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. Risk of accident $ 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. Instrument panel Actros 1 (up to 12/1999) Possible remedy M Stop the vehicle as soon as possible taking into account the traffic situation. M Switch off engine and apply parking brake. 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 Switch off engine and apply parking brake. M Check engine oil level, see page 89, and top up if necessary. 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. M Adjust your driving style. Reduce speed before corners in particular. M Have the steering system checked at a qualified workshop. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 23

26 Description and roadside assistance Instrument panel Actros 1 (up to 12/1999) Display messages on a red background Display message Possible cause/ consequence Four-axle vehicles: Steering circuit 2 has failed. The vehicle can only be steered with increased effort. The coolant level has dropped about 4 l below the normal fill level. The warning buzzer sounds. Risk of accident $ The 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 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. 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. The braking behavior of the vehicle is changed. Possible remedy M Adjust your driving style. Reduce speed before corners in particular. M Have the steering system checked at a qualified workshop. M Stop the vehicle as soon as possible taking into account the traffic situation. M Switch off engine and apply parking brake. M Top up coolant. M Have the cooling system checked for leaks at a qualified workshop. 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. M Have the brake linings replaced at a qualified workshop as quickly as possible. M Drive with special care. M Have the brake system checked at a qualified workshop. 24 i Guidelines for Breakdown Services (Subject to technical modifications)

27 Display messages on a red background Display message Possible cause/ consequence 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. Display failure (vehicles with Telligent automatic gearshift system). Important operating information and warnings can no longer be displayed. The handling and braking behavior of the vehicle may change. Risk of accident $ Display failure. Important operating information and warnings can no longer be displayed. The handling and braking behavior of the vehicle may change. Instrument panel Actros 1 (up to 12/1999) Possible remedy M Drive with special care. M Drive with special care. M Have the brake system checked at a qualified workshop. M Leave the clutch to cool and select a lower moving-off gear if necessary. M Fold out the clutch pedal and shift gears manually, see page 123. M Drive with special care. or M Tow the vehicle away, see page 169. M Drive with special care. or M Tow the vehicle away, see page 169. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 25

28 Description and roadside assistance 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 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 i Guidelines for Breakdown Services (Subject to technical modifications)

29 Indicator lamps Indicator lamp Description High beam Cab lock Cargo liftgate Frequent-stop brake Instrument panel Actros 1 (up to 12/1999) Description and roadside assistance 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) Guidelines for Breakdown Services (Subject to technical modifications) i 27

30 Description and roadside assistance 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 Operating information Warnings Display of malfunctions and failures of electronic systems Driver Information System (FIS), see page 31. 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. C STOP lamp, see page 39 D Multifunction display (MFD) Gear indicator, see page 30 Trip odometer Time. = Indicator lamps, see page 49 E Fuel level gauge, see page 30? Reservoir pressure, brake circuit 1, see page 29 A Function buttons for Driver Information System (FIS), see page 31 F G H Coolant temperature gauge Clock control buttons Auxiliary heater timer 28 i Guidelines for Breakdown Services (Subject to technical modifications)

31 Reservoir pressure gauge for brake circuits 1 and 2 : Reservoir pressure, brake circuit 1 ; Reservoir pressure, brake circuit 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. Instrument panel Actros 1 (as of 01/2000) Description and roadside assistance 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 brake 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. Guidelines for Breakdown Services (Subject to technical modifications) i 29

32 Description and roadside assistance 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 / High-speed splitter group 0 Low-speed splitter group 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 i Guidelines for Breakdown Services (Subject to technical modifications)

33 Driver Information System (FIS) Instrument panel Actros 1 (as of 01/2000) 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. Description and roadside assistance 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. Guidelines for Breakdown Services (Subject to technical modifications) i 31

34 Description and roadside assistance Instrument panel Actros 1 (as of 01/2000) Driver Information System (FIS) display : Display ; Memory field = Status indicator (yellow or red) 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. Display Status indicator Confirm display with function button T, see page 31 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 Malfunction class, see page i Guidelines for Breakdown Services (Subject to technical modifications)

35 Menus Instrument panel Actros 1 (as of 01/2000) 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 Fault Info Settings Service Info Check Info Equipment 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 Malfunctions in memory field. Language ART signal transmitter (Telligent distance control) Display differential locks Display NR (level control) Display separation (activate and deactivate display with dashes) Display maintenance system for general maintenance jobs according to the vehicle load. Axle load indicator Engine oil pressure Power take-off Other check information Engine operating hours Engine oil level Engine oil top-up quantity Operating states of the differential locks and Telligent level control. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 33

36 Description and roadside assistance 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 i Guidelines for Breakdown Services (Subject to technical modifications)

37 Note on display messages Instrument panel Actros 1 (as of 01/2000) Each malfunction in an electronic system (e.g. tachograph) is indicated 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. A M Press S button on instrument panel. Status indicator (yellow or red) Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 35

38 Description and roadside assistance 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) = Event code 2 Malfunction class The malfunction class is either "0", "1" or "2", see page 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 absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. 36 i Guidelines for Breakdown Services (Subject to technical modifications)

39 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 Instrument panel Actros 1 (as of 01/2000) Description and roadside assistance : Status indicator yellow ; Malfunction class "1" 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. Guidelines for Breakdown Services (Subject to technical modifications) i 37

40 Description and roadside assistance Instrument panel Actros 1 (as of 01/2000) Malfunction class 2 : Status indicator red ; Malfunction class "2" 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 absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. 38 i Guidelines for Breakdown Services (Subject to technical modifications)

41 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 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. Instrument panel Actros 1 (as of 01/2000) 1 Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 39

42 Description and roadside assistance 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 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: The wheels may lock up when braking. The lateral stability of the vehicle may change. M Drive with special care or tow the vehicle away, see page 169. AG Automatic gear selection M Fold out the clutch pedal and shift gears manually, see page 123. M Drive with special care. ART BS EAB Autonomous intelligent cruise control: Inoperative 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. 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. M Drive with special care. M Drive with special care or tow the vehicle away, see page 169. M Drive with special care or tow the vehicle away, see page 169. EDW Anti-theft alarm system M Have the system repaired. FFB Radio remote control M Lock/unlock the doors with the vehicle key. FLA Flame starting system (cold-starting aid): M Have the system repaired. If temperatures are below 4 C, the starting characteristics change. 40 i Guidelines for Breakdown Services (Subject to technical modifications)

43 Abbreviation Description Action Instrument panel Actros 1 (as of 01/2000) FR 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. 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 M Have the system repaired. INS Instrument cluster: Important information (warnings, malfunctions) can no longer be displayed. M Drive with special care. or M Tow the vehicle away, see page 169. KOM Communications interface M Have the system repaired. KS Clutch control Vehicles with Telligent automatic gearshift system M Drive with special care. M Fold out the clutch pedal and shift gears manually, see page 123. KSA Comfort locking system M Have the system repaired. MR NR PSM Engine control: Accelerator pedal inoperative and constant engine speed below 1300 rpm. Level control: The handling of the vehicle may change (e.g. chassis leans to one side, center of gravity changed). Parameterizable special module: Power take-off inoperative. 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. M If the engine speed is not sufficient to start off or drive, tow the vehicle away, see page 169. M Drive with special care. M Have the system repaired. RS Retarder control M Drive with special care. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 41

44 Description and roadside assistance Instrument panel Actros 1 (as of 01/2000) Abbreviation Description Action SIL Seat electronics, left M Have the system repaired. SIR Seat electronics, right M Have the system repaired. SPA Lane Assistant M Have the system repaired. SRS Supplemental restraint system M Have the system repaired. TCO Tachograph M Have the system repaired. WS Maintenance system M Have the system repaired. WSK Torque converter clutch: The handling of the vehicle may change. M Tow the vehicle away, see page 169. ZHE Auxiliary heater M Have the system repaired. ZV Central locking M Lock/unlock the doors with the vehicle key. 42 i Guidelines for Breakdown Services (Subject to technical modifications)

45 Display messages Display message with yellow status indicator Instrument panel Actros 1 (as of 01/2000) Display message Possible cause/consequence Possible remedy Risk of accident $ 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. Risk of accident $ The alternator is defective. The handling and braking behavior of the vehicle may change. 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. The oil level of the automatic engine oil refill system has dropped to about 3.5 l. M Stop the vehicle as soon as possible taking into account the traffic situation. M Switch off engine and apply parking brake. 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 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 fuse. M Check and replace the appropriate bulb. M Top up. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 43

46 Description and roadside assistance Instrument panel Actros 1 (as of 01/2000) Display message with yellow status indicator Display message Possible cause/consequence Possible remedy Engine oil level has dropped to minimum fill level. Coolant level has dropped about 2 l below the normal fill level. Coolant temperature is too high. The engine output is automatically reduced. Fuel level has dropped to about 14% of maximum fill level. M Top up. M Top up. M Demand less power from the engine. M Make sure that the air supply to the radiator is not obstructed. 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. The handling and braking behavior of the vehicle may change. The parking brake was not applied before engaging the PTO. Vehicles with Telligent automatic gearshift system: The parking brake was not applied before switching off the engine. 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 Apply parking brake. 44 i Guidelines for Breakdown Services (Subject to technical modifications)

47 Display message with yellow status indicator Risk of accident $ Fault in Telligent automatic gearshift system. The warning buzzer sounds. You cannot start the engine. Immobilizer is activated. Instrument panel Actros 1 (as of 01/2000) Display message Possible cause/consequence Possible remedy M Fold out the clutch pedal and shift gears manually, see page 123. M Drive with special care. M Wait until the warning buzzer stops. M Turn the vehicle key in the ignition lock all the way back. M Repeat the start attempt after about 2 seconds. Description and roadside assistance Display message with red status indicator Display message Possible cause/consequence Possible remedy Risk of accident $ 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. The engine oil pressure is too low. The warning buzzer sounds. The STOP lamp lights up. The operational safety of the engine is at risk. M Stop the vehicle as soon as possible taking into account the traffic situation. M Switch off engine and apply parking brake. 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 possible taking into account the traffic situation. M Switch off engine and apply parking brake. M Check engine oil level, see page 90, and top up. Guidelines for Breakdown Services (Subject to technical modifications) i 45

48 Description and roadside assistance Instrument panel Actros 1 (as of 01/2000) Display message with red status indicator Display message Possible cause/consequence 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 $ 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. Coolant level has dropped about 4 l below the normal fill level. The warning buzzer sounds. Risk of accident $ 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 Compressed air consumption too high while maneuvering Compressed air system leaking. The operational safety of the vehicle is at risk. M Check engine oil level, see page 90, and top up. M Top up steering oil and drive with special care. M Adjust your driving style. Reduce speed before corners in particular. M Have the steering system checked at a qualified workshop. M Stop the vehicle as soon as possible taking into account the traffic situation. M Switch off engine and apply parking brake. M Top up coolant. M Have the cooling system checked for leaks at a qualified workshop. M Top up the compressed air system or fill from an external source, see page 144. or M Tow the vehicle away, see page i Guidelines for Breakdown Services (Subject to technical modifications)

49 Display message with red status indicator Risk of accident $ The service limit of the brake linings has been reached. The braking behavior of the vehicle may change significantly. Instrument panel Actros 1 (as of 01/2000) Display message Possible cause/consequence Possible remedy 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. The braking behavior of the vehicle is changed. The retarder cannot be deactivated during ABS control or when depressing the accelerator pedal. M Drive with special care. M Have the brake linings replaced at a qualified workshop as quickly as possible. M Drive with special care. M Have the brake system checked at a qualified workshop. M Drive with special care. M Have the brake system checked at a qualified workshop. M Drive with special care. Description and roadside assistance 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. Guidelines for Breakdown Services (Subject to technical modifications) i 47

50 Description and roadside assistance Instrument panel Actros 1 (as of 01/2000) Display message with red status indicator Display message Possible cause/consequence Possible remedy Risk of accident $ Display failure. Important operating information and warnings can no longer be displayed. The handling and braking behavior of the vehicle may change. The service date has been significantly exceeded. M Drive with special care. M Tow the vehicle away, see page 169. M Perform service. M Have the service work performed at a qualified workshop. 48 i Guidelines for Breakdown Services (Subject to technical modifications)

51 Indicator lamps Indicator lamp Description Dumper body Instrument panel Actros 1 (as of 01/2000) 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 Description and roadside assistance 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 Guidelines for Breakdown Services (Subject to technical modifications) i 49

52 Description and roadside assistance Instrument panel Actros 2/3 (as of 01/2003) Overview: Actros 2 : Speedometer with display for trip mileage and total mileage Instrument panel, Actros 1 (up to 12/1999), see page 15. Instrument panel, Actros 1 (as of 01/2000), see page 28. Instrument panel, Actros 3 (as of 06/2008), see page 51. B Reservoir pressure gauge for brake circuit 1 or 2, see page 52 C Brake circuit 2 indicator lamp, see page 52 ; Indicator lamps, see page 84 D Brake circuit 1 indicator lamp, see page 52 = STOP lamp, see page 64 E Button for instrument illumination brighter? Display, see page 57 F Button for instrument illumination darker A Tachometer with Ecometer Clock Outside temperature indicator. G H RESET button Button for confirming display messages I Button for resetting trip mileage to "0" J Fuel level gauge, see page 55 K AdBlue level gauge, see page i Guidelines for Breakdown Services (Subject to technical modifications)

53 Overview: Actros 3 Instrument panel Actros 2/3 (as of 01/2003) Description and roadside assistance : Speedometer with display for trip mileage and total mileage Instrument panel, Actros 1 (up to 12/1999), see page 15. Instrument panel, Actros 1 (as of 01/2000), see page 28. Instrument panel, Actros 2 (as of 06/2008), see page 50. B Reservoir pressure gauge for brake circuit 1 or 2, see page 52 C Brake circuit 2 indicator lamp, see page 52 ; Indicator lamps, see page 84 D Brake circuit 1 indicator lamp, see page 52 = STOP lamp, see page 64 E Button for instrument illumination brighter? Display, see page 57 F Button for instrument illumination darker A Tachometer with Ecometer Clock Outside temperature indicator. G H RESET button Button for confirming display messages I Button for resetting trip mileage to "0" J Fuel level gauge, see page 55 K AdBlue level gauge, see page 55 Guidelines for Breakdown Services (Subject to technical modifications) i 51

54 Description and roadside assistance 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 brake 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. 52 i Guidelines for Breakdown Services (Subject to technical modifications)

55 Gear indicator Instrument panel Actros 2/3 (as of 01/2003) Telligent automatic gearshift system and Mercedes PowerShift (16-speed transmission) The display shows the following information: The engaged gear and the engaged splitter group : The transmission mode ; The active operating mode =. : / High-speed splitter group 0 Low-speed splitter group 1 8 1st to 8th gear N Transmission neutral 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 Description and roadside assistance Mercedes PowerShift (12-speed transmission) Depending on the transmission version, the display shows the following information: The engaged gear : The transmission mode ; The active operating mode =. : st to 12th gear N/E / N/E 0 R1 R4 Transmission neutral, highspeed splitter group Transmission neutral, lowspeed splitter group 1st to 4th reverse gear ; E EcoRoll mode P Power mode = A Automatic mode M Manual mode Gear indicator in display Guidelines for Breakdown Services (Subject to technical modifications) i 53

56 Description and roadside assistance 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 ;. / High-speed splitter group 0 Low-speed splitter group 1 8 1st to 8th gear N R Transmission neutral Reverse gear Gear indicator in display 54 i Guidelines for Breakdown Services (Subject to technical modifications)

57 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. + The fuel supply and range can be called up in the Trip computer menu. Instrument panel Actros 2/3 (as of 01/2003) Fuel/AdBlue level gauge (example on Actros 2) Description and roadside assistance AdBlue level gauge The AdBlue level gauge : only shows the approximate AdBlue level. The AdBlue level is indicated by 4 blue segments. + 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. 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 onboard computer menu under Actros Info/Check Info, see page 60. Guidelines for Breakdown Services (Subject to technical modifications) i 55

58 Description and roadside assistance 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 Telephone: ; Á Reset button: Reset trip data Reset trip counter : Accept call/redial 9 End call or direct access to telephone menu = T Confirm display messages C VU?? RESET button: A Confirm service work performed. Change operating fluid data in menu Settings/ submenu Operating fluids. 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. D Scroll up/down in main menu Confirm display message Return to main menu The most recently selected settings are saved automatically. Scroll in submenu (select function): & Forward 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. 56 i Guidelines for Breakdown Services (Subject to technical modifications)

59 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 B C D Gear indicator (transmissions with Telligent gearshift system, Telligent automatic gearshift system or Mercedes PowerShift) Reminder field (stored malfunctions or received SMS messages) Operation indicator for differential locks Operation indicator for cruise control, speed limiter, Telligent distance control, Active Brake Assist Instrument panel Actros 2/3 (as of 01/2003) Description and roadside assistance 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 indicated 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). Guidelines for Breakdown Services (Subject to technical modifications) i 57

60 Description and roadside assistance 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 Actros Info Check Info (see page 60) Trip computer (trip data) Maintenance Event Info (see page 61) Submenu Speed Date Clock AdBlue level gauge Coolant temperature Brake system reservoir pressure Oil level in engine Operating hours Axle loads Cargo monitoring Trailer ID number After start After reset Diesel fuel tank Driver 1 Time-based servicing Brakes A1-A4 Air filter Air drier Engine X General Transmission Rear axle Front axle Retarder Coolant Transfer case Malfunctions 58 i Guidelines for Breakdown Services (Subject to technical modifications)

61 Main menu Auxiliary heater Alarm clock Language Settings GS back-up mode (transmission emergency mode) (see page 128) Diagnosis (service personnel) Navigation (Audio APS 30) Audio (radio) SMS (FleetBoard ) Telephone Submenu Temperature Set temperature Heating duration Set memory Wakeup mode Wakeup time Configuration Cargo monitoring Clock Units Operating fluids Base functions in radio\cassette or CD player mode. Instrument panel Actros 2/3 (as of 01/2003) Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 59

62 Description and roadside assistance 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 1. VU Main menu Check Info 2. &* 9 AdBlue tank 90 l (example text) 9 Description The AdBlue level is 90 l. The display shows the current AdBlue level in a bar graph and in liters. The AdBlue supply is down to the reserve level. AdBlue reserve 9 AdBlue empty 9 AdBlue tank --- l 2. &* Coolant temperature ( C) The AdBlue supply is exhausted. The onboard computer cannot determine the AdBlue level. The engine coolant temperature ( C) 2. &* Reservoir pressure (\/ ^) Reservoir pressure in brake circuit 1/brake circuit bar / --.- bar 2. &* Oil level O.K. or -.- l / >max. Engine oil level O.K. or top-up quantity or overfilled 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) 60 i Guidelines for Breakdown Services (Subject to technical modifications)

63 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 Stored malfunctions: System abbreviation, see page 65, or symbol, see page 62, malfunction location, function restriction, instruction. 2. &* INS Speed logging disrupted Immediate service required (example text) 3. T or VU Instrument panel Actros 2/3 (as of 01/2003) Press T button (confirm display message). Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 61

64 Description and roadside assistance 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 : Status indicator (white, yellow or red) ; Symbol B Reminder field 62 i Guidelines for Breakdown Services (Subject to technical modifications)

65 Confirm display message M Press button T, V or U. Instrument panel Actros 2/3 (as of 01/2003) The display message disappears and can be called up in the Event Info menu, see page 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. Description and roadside assistance Display message with red status indicator Risk of accident $ The operational safety of the vehicle is compromised if there is 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 is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. Guidelines for Breakdown Services (Subject to technical modifications) i 63

66 Description and roadside assistance 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 absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. 64 i Guidelines for Breakdown Services (Subject to technical modifications)

67 System abbreviations System Abbreviation Abbreviation Instrument panel Actros 2/3 (as of 01/2003) System ABA Active Brake Assist KSA Comfort locking system ABS Antilock brake system MR Telligent engine control AG Automatic gear selection 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 Anti-theft alarm system SRS Supplemental restraint system 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 Communications interface ZL Telligent trailing axle KS Clutch control Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 65

68 Description and roadside assistance Instrument panel Actros 2/3 (as of 01/2003) Display messages Display message with white status indicator Display message VP VP VP Active Brake Assist Switched on Active Brake Assist Switched off Active Brake Assist Cannot be activated Emergency braking complete! Possible cause/ consequence Active Brake Assist is switched on. Active Brake Assist is switched off. 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. Risk of accident $ 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. Active Brake Assist had automatically initiated emergency braking (emergency stop). Emergency braking is complete. Possible remedy M Switch on Active Brake Assist. M Pay particular attention to the traffic situation. M Brake the vehicle with the service brake. M Have the Active Brake Assist system checked at a qualified workshop. 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 i Guidelines for Breakdown Services (Subject to technical modifications)

69 Display message with yellow status indicator Display message Possible cause/ consequence Instrument panel Actros 2/3 (as of 01/2003) Possible remedy 9P The fuel supply is exhausted. M Fill the fuel tank. 9P Top up AdBlue The AdBlue supply is down to the reserve level. 9P Top up diesel The fuel supply is down to the reserve level. 9P 9P P 4N 4P Refuel diesel, refueling AdBlue recommended Top up diesel and AdBlue Left brake lamp defective (example) The fuel supply is down to the reserve level. 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. The left brake lamp on the trailer/semitrailer is defective. 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 Fill AdBlue tank. M Fill the fuel tank. M Fill the fuel tank. M To avoid the need for another refueling stop, fill the AdBlue tank at the same time. M Fill the fuel tank. M Fill AdBlue tank. M Fill the reservoir of the windshield washer/headlamp cleaning system. M Check and replace the appropriate bulb (see operator's manual of trailer/semitrailer). M Check and replace the appropriate 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! Description and roadside assistance 0P 7.5 l (example) The engine oil level is too low. M Add the oil quantity shown in the display. 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 km or until the status indicator lights up red. Guidelines for Breakdown Services (Subject to technical modifications) i 67

70 Description and roadside assistance Instrument panel Actros 2/3 (as of 01/2003) Display message with yellow status indicator Display message P Air filter km (example) P Air filter service due (example) A service date is due shortly. A service date is due.,p The coolant level has dropped. M Schedule the service for the due date. M Have the service work performed at a qualified workshop. M Top up coolant. 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. :P Vehicles with Telligent automatic gearshift system: The reservoir pressure in the ancillary consumer circuit is too low. The Telligent automatic gearshift system is inoperative. BP Possible cause/ consequence Malfunction in the electronic drive control. The accelerator pedal is inoperative and the engine runs in limp-home mode. The engine output is reduced. Possible remedy M Stop the vehicle as soon as possible taking into account the traffic situation. 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. M Stop the vehicle, taking into account the traffic situation. M Apply parking brake. M Switch off the engine and restart. Activate engine limp-home mode: M Stop the vehicle, taking into account the traffic situation. M Switch off engine and apply parking brake. M Wait about 10 seconds and restart the engine. If the engine is still running in limphome mode: Have the fault rectified at a qualified specialist workshop. 68 i Guidelines for Breakdown Services (Subject to technical modifications)

71 Display message with yellow status indicator Display message BP The engine runs at a constant speed of 1300 rpm. Engine limp-home mode is activated. /P You cannot start the engine. /P Immobilizer activated. FP FN KN LN Wheel brake overloaded Possible cause/ consequence The starter batteries are discharged. You cannot start the engine. You have attempted to start the engine 5 times with an invalid vehicle key. The immobilizer is activated. The temperature at one wheel brake of the tractor vehicle is too high. The wheel brake may overheat. The temperature at one wheel brake on the trailer/ semitrailer is too high. The wheel brake may overheat. The cargo temperature set on the cargo monitor in the trailer/semitrailer has been exceeded or undershot. The cargo pressure set on the cargo monitor in the trailer/ semitrailer has been exceeded or undershot. Instrument panel Actros 2/3 (as of 01/2003) Possible remedy M Visit a qualified specialist workshop. M Repeat the start attempt after about 10 seconds. Note that excessively long start attempts drain the batteries. M Jump start the engine from another vehicle. 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. M Drive with special care. M Shift to a lower gear and use the permanent brake as much as possible to brake the vehicle. M Have the brake system checked at a qualified workshop. M Drive with special care. M Shift to a lower gear and use the permanent brake as much as possible to brake the vehicle. M Have the brake system checked at a qualified workshop. M Have the cargo monitoring system checked at a qualified workshop. M Have the cargo monitoring system checked at a qualified workshop. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 69

72 Description and roadside assistance Instrument panel Actros 2/3 (as of 01/2003) Display message with yellow status indicator Display message MN SN UP UP VP VP Clean distance sensor Distance control: Restrictions possible Active Brake Assist unavailable Active Brake Assist: Function restricted Possible cause/ consequence 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. The distance sensor is dirty. The Telligent distance control is malfunctioning. Active Brake Assist is unavailable. The vehicle will not be braked automatically in critical situations. You must brake the vehicle with the service brake. Active Brake Assist is malfunctioning. The vehicle will not be braked automatically in critical situations. You must brake the vehicle with the service brake. Possible remedy M Have the cargo monitoring system checked at a qualified workshop. M Observe the distance indicator in the display. M Clean the lens of the distance sensor 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. M Have the Telligent distance control checked at a qualified workshop. M Pay particular attention to the traffic situation. M Brake the vehicle with the service brake. M Have the Active Brake Assist system checked at a qualified workshop. M Pay particular attention to the traffic situation. M Brake the vehicle with the service brake. M Have the Active Brake Assist system checked at a qualified workshop. 70 i Guidelines for Breakdown Services (Subject to technical modifications)

73 Display message with yellow status indicator Display message GP Up to 05/2005: Clutch: Failure. Use GS back-up mode As of 06/2005 Clutch: Failure. Service required GP GP Gearshift: Failure. Perform major teach-in process Gearshift: Failure. Use GS back-up mode Possible cause/ consequence Risk of accident $ Vehicles with Telligent gearshift system/automatic gearshift system/mercedes PowerShift: Insufficient reservoir pressure in ancillary consumer circuit. The transmission can no longer shift. Risk of accident $ Vehicles with Telligent gearshift system/automatic gearshift system/mercedes PowerShift: The transmission can no longer shift. Risk of accident $ Vehicles with Telligent gearshift system/automatic gearshift system/mercedes PowerShift: Electronic system of transmission control is malfunctioning. The transmission can no longer shift. Instrument panel Actros 2/3 (as of 01/2003) Possible remedy M Stop the vehicle as soon as possible taking into account the traffic situation. 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. M Stop the vehicle as soon as possible taking into account the traffic situation. M Apply parking brake. M Switch off engine and apply parking brake. M Perform the "major teach-in process", see page 118. 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. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 71

74 Description and roadside assistance Instrument panel Actros 2/3 (as of 01/2003) Display message with yellow status indicator Display message GP 0P 0P 0P 0P Parameterization error. Perform major teach-in process Torque converter mode/ no accelerator shutoff Torque converter activated Torque converter: Permanently activated Torque converter: Restrictions possible Risk of accident $ Vehicles with Telligent gearshift system/automatic gearshift system/mercedes PowerShift: The transmission can no longer shift. No CAN link to the FR. Information on idle and kickdown speeds is missing. Torque converter mode is activated. There is a malfunction at the solenoid valve of the torque converter clutch. 0P Retarder lever! The function of the retarder is restricted. M Stop the vehicle as soon as possible taking into account the traffic situation. M Switch off engine and apply parking brake. M Perform the "major teach-in process", see page 118. M Have the torque converter clutch checked and repaired at a qualified workshop. - M Have the torque converter clutch checked and repaired at a qualified workshop. - M Have the torque converter clutch checked and repaired at a qualified workshop. The retarder is inoperative. The retarder operates with no function restrictions. 0P Retarder! The retarder cannot be shut off. 0P Valve! The retarder is inoperative. The retarder brake responds with a delay. 0P Temperature sensor! Possible cause/ consequence The torque converter is permanently active. The retarder operates with no function restrictions. The function of the retarder is restricted. Possible remedy M Have the torque converter clutch checked and repaired at a qualified workshop. M Have the torque converter clutch checked and repaired at a qualified workshop. M Have the torque converter clutch checked and repaired at a qualified workshop. M Have the torque converter clutch checked and repaired at a qualified workshop. 72 i Guidelines for Breakdown Services (Subject to technical modifications)

75 Display message with yellow status indicator Display message 0P Electronics! The function of the retarder is restricted. The retarder operates with no function restrictions. 0P Network! The retarder is inoperative. The torque converter is permanently active. 0P 0P Retarder: Restrictions possible Temperature of torque converter clutch too high Possible cause/ consequence Torque converter mode/no accelerator shutoff: No CAN link to the FR. Information on idle and kickdown speeds is missing. The retarder operates with no function restrictions. The retarder lever is inoperative. There is a malfunction of the temperature sensor. The vehicle was driven for too long in torque converter mode. 3P Risk of accident $ The voltage in the on-board electrical system has dropped below 22 V. The poly-v belt has snapped or the alternator is defective. The handling and braking behavior of the vehicle may change. Instrument panel Actros 2/3 (as of 01/2003) Possible remedy M Have the torque converter clutch checked and repaired at a qualified workshop. M Have the torque converter clutch checked and repaired at a qualified workshop. M Have the torque converter clutch checked and repaired at a qualified workshop. 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 taking into account the traffic situation. M Switch off engine and apply parking 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. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 73

76 Description and roadside assistance Instrument panel Actros 2/3 (as of 01/2003) Display message with yellow status indicator Display message 3P Risk of accident $ The alternator is defective. CN The braking behavior may change. Possible cause/ consequence The handling and braking behavior of the vehicle may change. Risk of accident $ Malfunction in brake system of trailer/semitrailer. Possible remedy 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 Have the brake system checked at a qualified workshop. The handling or braking properties of the vehicle may change. Up to 05/ 2005: MP Risk of accident $ Parking brake is not applied. 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. M Apply the parking brake when parking the vehicle. Up to 05/ 2005: MP Vehicles with parameterizable special module (PSM): Parking brake is not applied. 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. M Apply the parking brake before switching on the PTO. Up to 05/ 2005: P Air filter Immediate service (example) A service date has been significantly exceeded. Risk of damage to the vehicle and its major assemblies. M Have the service work performed at a qualified workshop. 74 i Guidelines for Breakdown Services (Subject to technical modifications)

77 Display message with yellow status indicator Display message Up to 05/ 2005: NP 6P Brake A1 Immediate service (example) The braking behavior may change. Visit a workshop at the first opportunity. Possible cause/ consequence Risk of accident $ Due service work has not been performed. The service limit of the brake linings or the brake disks has been exceeded. The handling and braking behavior of the vehicle may change. Risk of accident $ Malfunction in the brake system of the vehicle. The handling or braking properties of the vehicle may change. Instrument panel Actros 2/3 (as of 01/2003) Possible remedy M Have the brake linings replaced at a qualified workshop. M Have the brake system checked at a qualified workshop. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 75

78 Description and roadside assistance Instrument panel Actros 2/3 (as of 01/2003) Display message with yellow status indicator and warning buzzer Display message 0P ; DP ; /P ; Coolant temperature too high CODE Possible cause/ consequence Vehicles with Telligent automatic gearshift system: The permissible operating temperature of the clutch has been exceeded. There is a risk of clutch damage. The coolant temperature is too high. The engine output is automatically reduced. You cannot start the engine. The immobilizer is activated. You cannot start the engine. You have attempted to start the engine with an invalid vehicle key. The immobilizer is activate. S; The ramp distance is less than 50 cm. Possible remedy M Shift to a lower gear to maneuver the vehicle or to move off. M Finish the moving-off or maneuvering process as quickly as possible. 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. M Wait until the warning buzzer stops. M Turn the vehicle key in the ignition lock all the way back. M Repeat the start attempt after about 2 seconds. 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. 76 i Guidelines for Breakdown Services (Subject to technical modifications)

79 Display message with red status indicator Display message As of 06/ 2005 MP Engage parking brake Possible cause/ consequence Risk of accident $ Parking brake is not applied. 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. Instrument panel Actros 2/3 (as of 01/2003) Possible remedy M Apply the parking brake when parking the vehicle. Description and roadside assistance As of 06/ 2005 MP Engage parking brake 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 Air filter - Immediate service (example) A service date has been significantly exceeded. Risk of damage to the vehicle and its major assemblies. M Have the service work performed at a qualified workshop. As of 06/ 2005 NP Brake A1 - Immediate service (example) Risk of accident $ Due service work has not been performed. The service limit of the brake linings or the brake disks is past maximum. M Have the brake linings replaced at a qualified workshop. The handling and braking behavior of the vehicle may change. Guidelines for Breakdown Services (Subject to technical modifications) i 77

80 Description and roadside assistance Instrument panel Actros 2/3 (as of 01/2003) Display message with red status indicator Display message $P The alternator or the poly-v belt is defective. + P Power reduced There may be a fault in the exhaust aftertreatment system. + P Service required + P Service required Possible cause/ consequence The indicator lamp ; flashes. The engine output is reduced. Vehicles with Telligent automatic gearshift system/ Mercedes PowerShift: The transmission switches to manual mode. There is a fault in the exhaust aftertreatment system. The permissible emission levels are exceeded. The indicator lamp ; flashes. The NOx sensor is defective. Possible remedy M Stop the vehicle as soon as possible taking into account the traffic situation. M Switch off engine and apply parking brake. 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 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. 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. M Have the fault rectified at a qualified workshop. 78 i Guidelines for Breakdown Services (Subject to technical modifications)

81 Display message with red status indicator Display message 9P Power reduced Top up AdBlue Possible cause/ consequence The AdBlue supply is exhausted. The indicator lamp ; flashes. The engine output is reduced. Vehicles with Telligent automatic gearshift system/ Mercedes PowerShift: The transmission switches to manual mode. Instrument panel Actros 2/3 (as of 01/2003) Possible remedy M Fill AdBlue tank. M Shift the transmission manually. M Confirm the display message. 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. Description and roadside assistance 9P AdBlue empty The AdBlue supply is exhausted. M Fill AdBlue tank. 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 $ Malfunction in brake system of trailer/semitrailer. 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 As of 06/ 2005 CN The braking behavior is changed Risk of accident $ The full braking power is not available. M Continue driving with special care. M Shift to a low gear and use the permanent brake as much as possible to brake the vehicle. M Have the brake system checked at a qualified workshop. 6P Brake force increased Pedal travel lengthened Immediate service required Risk of accident $ Malfunction in the brake system of the vehicle. The handling or braking properties of the vehicle have changed. M Continue driving with special care. M Have the brake system checked at a qualified workshop. Guidelines for Breakdown Services (Subject to technical modifications) i 79

82 Description and roadside assistance Instrument panel Actros 2/3 (as of 01/2003) Display message with red status indicator Display message NP MN 7P 8N Brake linings fully worn The handling and braking behavior may change. Malfunction in trailer ABS Possible cause/ consequence Risk of accident $ 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. The handling and braking behavior of the vehicle may change. Risk of accident $ The trailer/semitrailer is braked automatically. Malfunction in the retarder control. The retarder is not deactivated during ABS control or when depressing the accelerator pedal. Risk of accident $ The antilock brake system (ABS) in the trailer/ semitrailer is not functioning. There is a risk of excessive braking at the trailer/ semitrailer. Possible remedy M Continue driving with special care. M Have the brake linings on the trailer/ semitrailer replaced at a qualified workshop as quickly as possible. M Continue driving with special care. M Avoid heavy braking, except in emergency situations, so that the wheels of the trailer/semitrailer do not lock up. M Have the trailer/semitrailer checked at a qualified workshop. M Continue driving with special care. M Have the retarder control checked at a qualified workshop. M Continue driving with special care. M Avoid heavy braking, except in emergency situations, so that the wheels of the trailer/semitrailer do not lock up. M Have the trailer/semitrailer ABS checked at a qualified workshop..p The oil level in the reservoir of the power steering system has dropped to the minimum fill level. IP Four-axle vehicles: Steering circuit 2 has failed. The vehicle can only be steered with increased effort. M Have the steering system checked at a qualified workshop. M Adjust your driving style. Reduce speed before corners in particular. M Have the steering system checked at a qualified workshop. 80 i Guidelines for Breakdown Services (Subject to technical modifications)

83 Display message with red status indicator Display message Possible cause/ consequence /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. 0P Converter temp. The vehicle was driven for too long in torque converter mode. Instrument panel Actros 2/3 (as of 01/2003) Possible remedy M Have at least 2 liters of oil extracted 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). 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. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 81

84 Description and roadside assistance Instrument panel Actros 2/3 (as of 01/2003) Display message with red status indicator and warning buzzer Display message Possible cause/ consequence ; Risk of accident $ During an automatic distance warning it is absolutely essential to brake the vehicle with the service brake when: 5P ;,P ; The display shows with red status indicator A double warning tone sounds A constant warning buzzer sounds 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. Possible remedy M Pay particular attention to the traffic situation. M Brake the vehicle with the service brake. M Stop the vehicle as soon as possible taking into account the traffic situation. M Switch off engine and apply parking brake. M Notify a qualified specialist workshop. M Stop the vehicle as soon as possible taking into account the traffic situation. M Switch off engine and apply parking brake. M Top up coolant. M Have the cooling system checked for leaks at a qualified workshop. 82 i Guidelines for Breakdown Services (Subject to technical modifications)

85 Display message with red status indicator and STOP lamp Display message OP Possible cause/ consequence Risk of accident $ The 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 The operational safety of the vehicle is at risk. Instrument panel Actros 2/3 (as of 01/2003) Possible remedy M Stop the vehicle as soon as possible taking into account the traffic situation. 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. M Have the compressed air brake system checked for leaks at a qualified workshop. Description and roadside assistance Display message with red status indicator, warning buzzer and STOP lamp Display message.p ; 0P ; 12.5 l (example) Possible cause/ consequence The engine oil pressure is too low. The operational safety of the engine is at risk. The engine oil level is significantly too low. The operational safety of the engine is at risk. Possible remedy M Stop the vehicle as soon as possible taking into account the traffic situation. M Switch off engine and apply parking brake. M Check engine oil level, see page 90, and top up. M Notify a qualified specialist workshop. M Stop the vehicle as soon as possible taking into account the traffic situation. M Switch off engine and apply parking brake. 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. Guidelines for Breakdown Services (Subject to technical modifications) i 83

86 Description and roadside assistance Instrument panel Actros 2/3 (as of 01/2003) Indicator lamps Indicator lamp G I H J M K V Function Turn signal indicator, tractor vehicle, left Turn signal indicator, trailer/semitrailer, left Turn signal indicator, trailer/semitrailer, right Turn signal indicator, tractor vehicle, right Low beam High beam Permanent brake! Parking brake x Frequent-stop brake STOP lamp H d W Cab lock Acceleration skid control (ASR)/Telligent stability control (SR) Permanent brake; Telligent automatic gearshift system ; Engine diagnosis % Flame starting system (cold-starting aid) Ô X Õ Z G D Ò Lane Assistant (SPA) Torque converter clutch (WSK) Telligent trailing axle Hill holder Dumper body Cargo liftgate Stationary air conditioner 84 i Guidelines for Breakdown Services (Subject to technical modifications)

87 Engine diagnosis indicator lamp Instrument panel Actros 2/3 (as of 01/2003) 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 cause/consequence Possible remedy The indicator lamp ; lights up briefly. The indicator lamp ; flashes. At the same time the display shows a display message with red status indicator: 9P The indicator lamp ; lights up. 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. The engine output may be reduced. 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. The engine output may be reduced. - M Fill AdBlue tank immediately. M Have the BlueTec exhaust aftertreatment system checked as quickly as possible at a qualified specialist workshop. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 85

88 Description and roadside assistance 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. The STOP lamp lights up at the same time. The operational safety of the vehicle is at risk. Engine damage is possible. 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. 0. M Check engine oil level. Actros 1 (up to 12/1999), see page 89. Actros 1 (as of 01/2000), see page 90. Actros 2/3 (as of 01/2003), see page 91. M Tow the vehicle away, see page 169. Malfunctions in certain electronic systems. The operational safety of the vehicle is at risk. Engine damage is possible. Maximum permissible engine speed exceeded. The operational safety of the vehicle is at risk. Engine damage is possible. Coolant level too low or coolant temperature too high. The operational safety of the vehicle is at risk. Engine damage is possible. 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. M If the warning buzzer sounds when shifting down, select a higher gear. M If the warning buzzer sounds when tow-starting, 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 i Guidelines for Breakdown Services (Subject to technical modifications)

89 Warning buzzer ; sounds when Display Action Permissible coolant temperature exceeded. 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. Up to 05/ 2005: D As of 06/ 2005 D P x Warning buzzer M Demand less power from the engine. 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. M Fold out clutch pedal, see page 123. 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. Description and roadside assistance 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 Activated immobilizer. / P M Operate service brake; apply parking brake if necessary. + The hill holder is merely an aid intended to provide assistance when moving off. M Wait until the warning buzzer stops. M Turn the vehicle key in the ignition lock all the way back. 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. Guidelines for Breakdown Services (Subject to technical modifications) i 87

90 Description and roadside assistance 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. Telligent automatic gearshift system when the clutch is overloaded. Display failure. S Up to 05/ 2005: 0 As of 06/ P 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. M Leave the clutch to cool and select a lower moving-off gear if necessary. 5 M Tow the vehicle away, see page 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. 5P M Tow the vehicle away, see page 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. The seat belt on the driver seat is not buckled. M Switch off lights. 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 i Guidelines for Breakdown Services (Subject to technical modifications)

91 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! Oil level in engine Description and roadside assistance Checking engine oil pressure M Start engine. M Press "SYSTEM" button once or twice. The display shows the operating hours :. M Press "INFO" button twice. 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 Guidelines for Breakdown Services (Subject to technical modifications) i 89

92 Description and roadside assistance 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! 1 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 i Guidelines for Breakdown Services (Subject to technical modifications)

93 Actros 2/3: Calling up the engine oil level in the display Oil level in engine 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) Description and roadside assistance! Only top up the engine oil when the display shows 0 with a yellow status indicator. Guidelines for Breakdown Services (Subject to technical modifications) i 91

94 Description and roadside assistance 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 92 i Guidelines for Breakdown Services (Subject to technical modifications)

95 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. Fuel system Description and roadside assistance 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. Guidelines for Breakdown Services (Subject to technical modifications) i 93

96 Fuel system Description and roadside assistance Combination tank Filler neck : Diesel fuel ; Hydraulic fluid The combination tank consists of two separate chambers for diesel fuel and hydraulic fluid. + It is possible for the hydraulic tank to be installed separately. 1 2 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 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 i Guidelines for Breakdown Services (Subject to technical modifications)

97 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. Fuel system Description and roadside assistance : or? Hand pump ; or = Fuel prefilter with heated water separator Guidelines for Breakdown Services (Subject to technical modifications) i 95

98 Description and roadside assistance 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. 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 i Guidelines for Breakdown Services (Subject to technical modifications)

99 Fuel system System with fuel prefilter M Before bleeding, check whether water has settled in the sightglass :. If water has settled in the sightglass :, drain water from fuel system. 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/ fuel mixture. M Tighten drain screw ;. M Open knurled screw? on fuel prefilter Description and roadside assistance 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. Guidelines for Breakdown Services (Subject to technical modifications) i 97

100 Description and roadside assistance 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? Batteries behind the cab on heavy-duty tractor units (SLT) C D RESET switch (export vehicles for France), see page 101 Jump-start connection point (semitrailer tractors with integral rear end), see page i Guidelines for Breakdown Services (Subject to technical modifications)

101 EMERGENCY OFF switch Electrical system 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. Description and roadside assistance 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 :. Guidelines for Breakdown Services (Subject to technical modifications) i 99

102 Description and roadside assistance 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 Turn the vehicle key in the ignition lock all the way back. M Press cover of EMERGENCY OFF switch down until it clicks into place. M Turn vehicle key in ignition lock to drive position. The power supply to all consumers is restored. EMERGENCY OFF switch, Actros 2/3 100 i Guidelines for Breakdown Services (Subject to technical modifications)

103 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 Turn the vehicle key in the ignition lock all the way back. 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. 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. Electrical system 1 Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 101

104 Description and roadside assistance 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 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 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 i Guidelines for Breakdown Services (Subject to technical modifications)

105 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. Description and roadside assistance Vehicle supplying power: M Run the engine at a high speed. Vehicle receiving power: M Turn vehicle key in ignition lock to drive position. On vehicles with cold-starting aid, make sure that the indicator 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. Guidelines for Breakdown Services (Subject to technical modifications) i 103

106 Description and roadside assistance 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 injury 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 104 i Guidelines for Breakdown Services (Subject to technical modifications)

107 Batteries Electrical system Risk of explosion/injury $ A D B E C F Risk of explosion Charging batteries produces explosive oxyhydrogen gas. Batteries should only be charged in wellventilated rooms. Risk of explosion Avoid producing sparks! Do not use fire or open flames near batteries, and do not smoke. 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. 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! Keep children away. Children are incapable of appreciating the dangers of handling batteries and acid. When handling batteries, always comply with the safety information, precautions and procedures contained in the operating instructions. Description and roadside assistance Environmental warning % K I Batteries contain pollutants. Old batteries must not be discarded with household refuse. 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. Guidelines for Breakdown Services (Subject to technical modifications) i 105

108 Description and roadside assistance 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 with 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 i Guidelines for Breakdown Services (Subject to technical modifications)

109 Battery tray Electrical system 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. Description and roadside assistance 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. Guidelines for Breakdown Services (Subject to technical modifications) i 107

110 Description and roadside assistance 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 i Guidelines for Breakdown Services (Subject to technical modifications)

111 Overview of gearshift Manual gearshift system (HPS) (see page 110) Gearshift Description and roadside assistance 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 Guidelines for Breakdown Services (Subject to technical modifications) i 109

112 Description and roadside assistance 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 splitter 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 absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. 110 i Guidelines for Breakdown Services (Subject to technical modifications)

113 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. Gearshift 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 absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. Description and roadside assistance Actros 1 Actros 2/3 d Left-hand drive vehicles e Right-hand drive vehicles : Neutral button ; Gearshift lever 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. Guidelines for Breakdown Services (Subject to technical modifications) i 111

114 Description and roadside assistance 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 i Guidelines for Breakdown Services (Subject to technical modifications)

115 Telligent automatic gearshift system and Mercedes PowerShift Gearshift 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 absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop. Description and roadside assistance Actros 1 Telligent automatic gearshift system (16-speed transmission) Actros 2/3 Telligent automatic gearshift system (16-speed transmission) Mercedes PowerShift (12-speed transmission) Mercedes PowerShift (16-speed transmission) d e Left-hand drive vehicles 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 Guidelines for Breakdown Services (Subject to technical modifications) i 113

116 Description and roadside assistance Gearshift Operating modes In vehicles without fleet mode and vehicles with 16- speed 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 performed 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 i Guidelines for Breakdown Services (Subject to technical modifications)

117 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. Gearshift Description and roadside assistance 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. Guidelines for Breakdown Services (Subject to technical modifications) i 115

118 Description and roadside assistance 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 i Guidelines for Breakdown Services (Subject to technical modifications)

119 Vehicles with Mercedes PowerShift Gearshift 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. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 117

120 Description and roadside assistance 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 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 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 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. M When the display shows N, start the engine. A signal tone and a shift noise can be heard from the central speaker. 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. 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 i Guidelines for Breakdown Services (Subject to technical modifications)

121 M Release neutral button and function button. Gearshift 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 qualified 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 GS 19 Vehicle rolling. M Apply parking brake. M Repeat teach-in process. 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. GS 20 The display shows U <<<. M Charge or replace the battery. GS 21 GS 22 The clutch pedal was released too early or too late during the teach-in process. The neutral button was not released during the teach-in process. M Depress and release the clutch pedal at the right time (listen for the warning buzzer). M Press and hold down neutral button. GS 23 Teach-in errors M Perform major teach-in process. GS 24 GS 25 Parking brake not applied during the teach-in process. Emergency shift operated during teach-in process. M Apply parking brake. M Do not operate emergency shift. GS 26 Engine running M Minor teach-in process: Switch off the engine. 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. The clutch pedal was not fully depressed during the teach-in process. M Do not depress the accelerator pedal during the teach-in process. M Repeat teach-in process. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 119

122 Description and roadside assistance Gearshift Emergency shift of manual gearshift system (HPS) : 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 i Guidelines for Breakdown Services (Subject to technical modifications)

123 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. Gearshift Description and roadside assistance (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. Starting off (Gear lever on right side of transmission)! 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. Guidelines for Breakdown Services (Subject to technical modifications) i 121

124 Description and roadside assistance Gearshift Shifting reverse gear! In order to shift reverse gear, the help of a second person is necessary. 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) 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)! 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. 122 i Guidelines for Breakdown Services (Subject to technical modifications)

125 Emergency shift of Telligent gearshift system and Telligent automatic gearshift system (Actros 1) General information Gearshift 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 Description and roadside assistance Folding out clutch pedal M Turn vehicle key in ignition lock to drive position; the warning buzzer sounds. 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 1 Guidelines for Breakdown Services (Subject to technical modifications) i 123

126 Description and roadside assistance 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 i Guidelines for Breakdown Services (Subject to technical modifications)

127 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: Gearshift 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. Description and roadside assistance 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. Guidelines for Breakdown Services (Subject to technical modifications) i 125

128 Description and roadside assistance 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 i Guidelines for Breakdown Services (Subject to technical modifications)

129 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. Gearshift Description and roadside assistance 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! 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 Depress clutch pedal. M Start engine. M Release parking brake. M Slowly release clutch pedal and slowly depress accelerator pedal. Guidelines for Breakdown Services (Subject to technical modifications) i 127

130 Description and roadside assistance 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 in 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 i Guidelines for Breakdown Services (Subject to technical modifications)

131 GS back-up mode: Vehicles with Telligent gearshift system Starting off 1 VU GS back-up mode Engage parking brake before gear selection 2 &* Select gear Low gear/high gear 3 WX Select gear Low gear/high gear 4 &* Depress clutch Clutch depressed?/yes/no Gear indicator N N Gearshift Description GS back-up mode activated N Select gear (5, 2, R) N Description and roadside assistance 5 Fully depress clutch pedal. Depress clutch Clutch depressed?/yes/no N 6 WX Yes N Confirm 7 &* GS back-up mode Engage parking brake before gear selection 2, 5 or R 8 Release clutch pedal and slowly depress accelerator pedal. GS back-up mode Engage parking brake before gear selection 2, 5 or R Vehicle moves off Stopping, changing gear or transmission in neutral Gear indicator Description 1 Depress clutch pedal. 2 Brake vehicle to a standstill with brake pedal. GS back-up mode Engage parking brake before gear selection 5, 2, N or R Stop the vehicle. Observe the traffic situation. It is not possible to change gears while driving. 3 &* Select gear 5, 2, N or R Guidelines for Breakdown Services (Subject to technical modifications) i 129

132 Description and roadside assistance 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 1 VU GS back-up mode Engage parking brake before gear selection 2 &* Select gear Low gear/high gear/n/r/towing Gear indicator N N Description GS back-up mode activated 3 WX Select gear Towing 4 &* Depress clutch Clutch depressed?/yes/no N N Select Towing 5 Fully depress clutch pedal. Depress clutch Clutch depressed?/yes/no N 6 WX Yes N Confirm 7 &* GS back-up mode Towing N 8 Release clutch pedal. GS back-up mode Towing N Towing mode is activated 130 i Guidelines for Breakdown Services (Subject to technical modifications)

133 GS back-up mode: Vehicles with Telligent automatic gearshift system or Mercedes PowerShift Starting off M Select manual mode M. 1 VU GS back-up mode Engage parking brake before gear selection 2 &* Select gear Low gear/high gear 3 WX Select gear Low gear/high gear 4 &* GS back-up mode Engage parking brake before gear selection 5 Slowly depress accelerator pedal. GS back-up mode Engage parking brake before gear selection Gear indicator N N Description Gearshift GS back-up mode activated N Select gear (5, 2, R) 1 2, 5 or R 1 1, 7 or R 2 Select gear (7, 1, R) 2 2, 5 or R 1 Vehicle moves off 1, 7 or R 2 Description and roadside assistance speed transmission 12-speed transmission Stopping, changing gear or transmission in neutral Gear indicator Description 1 Brake vehicle to a standstill with brake pedal. 2 &* Select gear N GS back-up mode Engage parking brake before gear selection 2, 5, N or R 1 Stop the vehicle. Observe the 1, 7, N or R 2 traffic situation. It is not possible to change gears while driving. 2, 5, N or R 1 1, 7, N or R speed transmission 2 12-speed transmission 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. Guidelines for Breakdown Services (Subject to technical modifications) i 131

134 Gearshift Description and roadside assistance Towing mode M Select automatic mode A. 1 VU GS back-up mode Engage parking brake before gear selection 2 &* Select gear Towing 3 WX Select gear Towing Gear indicator N N N Description GS back-up mode activated Select Towing 4 &* GS back-up mode Towing 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 i Guidelines for Breakdown Services (Subject to technical modifications)

135 Emergency shift (live PTO) Gearshift 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. Description and roadside assistance 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 =. Guidelines for Breakdown Services (Subject to technical modifications) i 133

136 Description and roadside assistance 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. 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 Air- Processing Unit (EAPU): The pressure regulator, compressed air drier, multi-circuit protection valve, pressure limiting valves and control electronics are combined in one mechatronic unit. 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. Pressure regulating system Conventional constant pressure system Constant pressure system with Electronic Air-Processing Unit (EAPU) 134 i Guidelines for Breakdown Services (Subject to technical modifications)

137 Pressure regulating system Compressed air production 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 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). Description and roadside assistance 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 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 bar 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. Guidelines for Breakdown Services (Subject to technical modifications) i 135

138 Description and roadside assistance Compressed air production 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 drier 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 is 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 i Guidelines for Breakdown Services (Subject to technical modifications)

139 Pressure table Compressed air production 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. Operating pressures Operating pressure, rear and front axle brake circuit supply (connections 21 and 22) Operating pressure, trailer control, ancillary consumers, parking brake and transmission control supply, clutch operating system (connections 23 to 26) Opening and closing pressures Opening pressure, rear and front axle brake circuit supply (connections 21, 22) Closing pressure, 1 front and rear axle brake circuit supply (connections 21, 22) Opening pressure, trailer control and parking brake (connections 23, 25) Closing pressure 1, trailer control and parking brake (connections 23, 25) Opening pressure, ancillary consumers (connection 24) Closing pressure 1, ancillary consumers (connection 24) Opening pressure, transmission control, clutch operating system (connection 26) Closing pressure 1, transmission control, clutch operating system (connection 26) Spring-loaded actuator Release pressure (reservoir pressure in compressed air system) Release pressure (with external compressed air source) Pressure regulating system Conventional constant pressure system Conventional constant pressure system with Electronic Air- Processing Unit bar bar bar bar bar bar bar bar bar min. 4.5 bar min. 4.5 bar min. 4.5 bar bar bar bar min. 4.5 bar min. 4.5 bar min. 4.5 bar bar bar bar min. 4.5 bar min. 4.5 bar min. 4.5 bar bar min. 4.5 bar min. 8.0 bar min. 8.0 bar min. 8.0 bar min. 6.5 bar min. 6.5 bar min. 6.5 bar Description and roadside assistance 1 Closing pressure = static safety pressure (without replenishment and with 0 bar in the defective circuit) Guidelines for Breakdown Services (Subject to technical modifications) i 137

140 Description and roadside assistance 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 brake 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. 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 intact 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 i Guidelines for Breakdown Services (Subject to technical modifications)

141 Frequent-stop brake Brake system 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 brakes open automatically. It is not necessary to release the brakes manually. In comparison with the hill holder, which acts exclusively as a starting-off aid, the frequent-stop brake maintains the brake pressure even when the clutch or brake pedal is not operated. The frequent-stop brake requires less compressed air than the parking brake. Description and roadside assistance 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. M Apply parking brake. Guidelines for Breakdown Services (Subject to technical modifications) i 139

142 Description and roadside assistance 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 lever 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 pressure 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 i Guidelines for Breakdown Services (Subject to technical modifications)

143 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 Description and roadside assistance 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 it is switched off or has failed. Brake the vehicle with the service brake. Guidelines for Breakdown Services (Subject to technical modifications) i 141

144 Description and roadside assistance 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 i Guidelines for Breakdown Services (Subject to technical modifications)

145 Location of components (example: semitrailer variant) Brake system Description and roadside assistance : 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 F Four-circuit protection valve 1 brake)? Combination brake cylinder G Air drier with integrated pressure regulator 1 A B C Compressed air reservoir (trailer/semitrailer brake) Compressed air reservoir (clutch operating system/gearshift) Compressed air reservoir (rear axle service brake) H I Constant pressure reservoir Front coupling head (special equipment for Actros 1) 1 Location: On the implement carrier or on the inside of the frame (special equipment). Guidelines for Breakdown Services (Subject to technical modifications) i 143

146 Description and roadside assistance 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 i Guidelines for Breakdown Services (Subject to technical modifications)

147 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 :. 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. Brake system Vehicles with single-chamber air drier Description and roadside assistance Vehicles with dual-chamber air drier Vehicles with Electronic Air-Processing Unit (EAPU) Guidelines for Breakdown Services (Subject to technical modifications) i 145

148 Description and roadside assistance 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 i Guidelines for Breakdown Services (Subject to technical modifications)

149 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 dirt and no damp air is allowed to enter the compressed air system. 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. Brake system Vehicles with single-chamber air drier Description and roadside assistance Vehicles with dual-chamber air drier Vehicles with Electronic Air-Processing Unit (EAPU) Guidelines for Breakdown Services (Subject to technical modifications) i 147

150 Description and roadside assistance 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 drier/ 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 i Guidelines for Breakdown Services (Subject to technical modifications)

151 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 Brake system Actros 1/2 with single-chamber air drier and pressure regulating system Description and roadside assistance 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 Guidelines for Breakdown Services (Subject to technical modifications) i 149

152 Description and roadside assistance 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 parking 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 Spring brake cylinder with release indicator : Driving position ; Release position 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: mm 150 i Guidelines for Breakdown Services (Subject to technical modifications)

153 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. Brake system! 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. Description and roadside assistance Guidelines for Breakdown Services (Subject to technical modifications) i 151

154 Description and roadside assistance Telligent level control Diagram of Telligent level control : Telligent level control operating unit (beside driver seat) ; Valve block (front axle) A Bellows = Air suspension filler connection and test connections? Compressed air reservoir B Valve block (rear axle) 152 i Guidelines for Breakdown Services (Subject to technical modifications)

155 General Telligent level control 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 driving with a level other than the normal level (driving position). Only drive the vehicle at the normal level (driving position) wherever possible. Description and roadside assistance + 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 holder 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. Guidelines for Breakdown Services (Subject to technical modifications) i 153

156 Description and roadside assistance Telligent level control : 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 D E F Driving position (normal level) Raise Lower 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 i Guidelines for Breakdown Services (Subject to technical modifications)

157 Maintaining the level A constant chassis height can be saved for loading and unloading the vehicle. M Apply parking brake. Telligent level control 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. Description and roadside assistance 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. Guidelines for Breakdown Services (Subject to technical modifications) i 155

158 Description and roadside assistance Telligent level control 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 2 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 i Guidelines for Breakdown Services (Subject to technical modifications)

159 Tilting the cab Before tilting the cab M Apply parking brake. Tilting the cab 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. Description and roadside assistance 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. Guidelines for Breakdown Services (Subject to technical modifications) i 157

160 Description and roadside assistance 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 before switching it back on. 1 Vehicles with mechanical/hydraulic cab tilting system 2 1 Actros 1 Actros 2/3 : Tilt to driving position ; Tilt forward 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 i Guidelines for Breakdown Services (Subject to technical modifications)

161 Tilting back to driving position: Tilting the cab 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 $ Description and roadside assistance 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. Guidelines for Breakdown Services (Subject to technical modifications) i 159

162 Description and roadside assistance Tilting the cab Actros 1 Actros 2/ : 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 i Guidelines for Breakdown Services (Subject to technical modifications)

163 Tilting back to driving position Tilting the cab 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. Description and roadside assistance 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. Guidelines for Breakdown Services (Subject to technical modifications) i 161

164 Description and roadside assistance Tilting the cab Actros 1 Module A1 Fuse F13 Actros 2/3 Module A2 Fuse F2 162 i Guidelines for Breakdown Services (Subject to technical modifications)

165 Starting and stopping the engine with the cab tilted M Turn vehicle key in ignition lock to drive position. M Tilt cab forwards, see page 157. Vehicles with 2 pushbuttons on the engine Engine 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. Description and roadside assistance : 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. Guidelines for Breakdown Services (Subject to technical modifications) i 163

166 Description and roadside assistance 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 i Guidelines for Breakdown Services (Subject to technical modifications)

167 General Tow-starting Risk of accident $ Tow-starting If the reservoir pressure in the compressed air system is too low or nonexistent (warning lamp lights 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, fill the compressed air system from an external source before tow-starting, see page 144 If the engine is not running, only tow-start the vehicle on a straight stretch of road (no power steering) Only use a tow bar Risk of skidding on wet or slippery roads Do not tow-start in the reversing direction with reverse gear engaged If spring-loaded brake cylinders have been mechanically released, the parking brake is inoperative Do not tow-start if there is engine, transmission, transfer case, axle or steering damage Only tow-start the vehicle with the batteries connected. Risk of accident $ When tow-starting, the retarder (eddy current brake) in the vehicle may perform uncontrolled braking 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. 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. Guidelines for Breakdown Services (Subject to technical modifications) i 165

168 Tow-starting 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 i Guidelines for Breakdown Services (Subject to technical modifications)

169 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. Tow-starting Guidelines for Breakdown Services (Subject to technical modifications) i 167

170 Towing 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 i Guidelines for Breakdown Services (Subject to technical modifications)

171 General Towing Towing 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 power 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. Guidelines for Breakdown Services (Subject to technical modifications) i 169

172 Towing 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 i Guidelines for Breakdown Services (Subject to technical modifications)

173 Propeller shaft removal Towing Towing 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. 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 4 x 2 B B - 4 x 4 A and B B A 6 x 2 B B - 6 x 4 B B - 6 x 6 B B A 8 x 4 B B - 8 x 6 A and B B - 8 x 8 A and B B - Guidelines for Breakdown Services (Subject to technical modifications) i 171

174 Towing 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 i Guidelines for Breakdown Services (Subject to technical modifications)

175 Switching transfer case to road position Towing Towing 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. Guidelines for Breakdown Services (Subject to technical modifications) i 173

176 Towing 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 i Guidelines for Breakdown Services (Subject to technical modifications)

177 M Actros 1: Connect compressed air supply line of 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. Towing Towing! 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. Guidelines for Breakdown Services (Subject to technical modifications) i 175

178 Towing 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 i Guidelines for Breakdown Services (Subject to technical modifications)

179 Drive shafts Towing Towing 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 Transmission damage : Transfer case damage = Rear axle damage A, C Front axle damage E, G Wheel bearing/planetary hub reduction drive The engine stalls without propeller shaft ; moving. Propeller shaft ; moves. Propeller shafts? and D do not move. The engine/transmission block twists in the frame. In vehicles with transfer case the propeller shafts ;, D and F also move. Propeller shafts ;,? and B move. Propeller shafts D and F do not move. The intact wheel turns. Guidelines for Breakdown Services (Subject to technical modifications) i 177

180 Towing 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 cylinder 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 dirt. Special tools, see page i Guidelines for Breakdown Services (Subject to technical modifications)

181 Removing drive shafts on rear axles HL 7 and HD 7: Towing Towing 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. Guidelines for Breakdown Services (Subject to technical modifications) i 179

182 Towing 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 i Guidelines for Breakdown Services (Subject to technical modifications)

183 Towing in raised position Towing Towing! 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 semitrailer: 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). Guidelines for Breakdown Services (Subject to technical modifications) i 181

184 Towing Towing Overview of towing options Vehicle model Raised at the front by Raised at the rear by (7) 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 4 x 2 x x 1 x 1, 2, 6 x x 1 4 x 4 x x 1 x x 1 6 x 2 x x 1 x 1, 2, 6 x 1 6 x 2/4 x x 1 x 1, 2, 6 x 1 x 1 6 x 4 x x 1 x 1 x 1 6 x 6 x x 1 x 1 8 x 4/4, 8 x 6/4, 8 x 8/4 x 2, 4 Not permissible Not permissible End crossmember (3) Not permissible Empty vehicle only Only as far as the nearest unloading station at max. 10 km/h Semitrailer tractor only Remove wheels from 2nd front axle, secure brake drums Make sure suitable axle forks are used (axle diameter and width) See "Air-sprung vehicles" on page 185 Additionally secure the steering wheel and remove the roof spoiler 182 i Guidelines for Breakdown Services (Subject to technical modifications)

185 Raising by the wheels Towing Towing 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 with 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 touch 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. Guidelines for Breakdown Services (Subject to technical modifications) i 183

186 Towing 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 i Guidelines for Breakdown Services (Subject to technical modifications)

187 Air-sprung vehicles Towing Towing! 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 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 can lead to distortion at the cargo area. Guidelines for Breakdown Services (Subject to technical modifications) i 185

188 Towing Towing Raising by the leaf springs (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 i Guidelines for Breakdown Services (Subject to technical modifications)

189 Raising by the rear wheels Towing Towing 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.! 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. Guidelines for Breakdown Services (Subject to technical modifications) i 187

190 Towing 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 i Guidelines for Breakdown Services (Subject to technical modifications)

191 Gearshift Towing Towing 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. Special tools, see page ! On vehicles with a TELMA transmission, it is not possible to shift the high-speed splitter groups on the transmission. GP 2 Guidelines for Breakdown Services (Subject to technical modifications) i 189

192 Recovery 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 vicinity 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 i Guidelines for Breakdown Services (Subject to technical modifications)

193 Super-wide tires Recovery Recovery 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 tire 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. Guidelines for Breakdown Services (Subject to technical modifications) i 191

194 Recovery 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 i Guidelines for Breakdown Services (Subject to technical modifications)

195 Recovering the vehicle from the rear 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. Recovery Recovery 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. Guidelines for Breakdown Services (Subject to technical modifications) i 193

196 Recovery Recovery M Fit the straps : so that detachable parts, stabilizer bars, hoses and cables are not damaged. 194 i Guidelines for Breakdown Services (Subject to technical modifications)

197 Safety components When recovering a vehicle, pay attention to the following safety components: Frame Longitudinal members and crossmembers. Cab Cab mounting including catch. Recovery Recovery 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. Guidelines for Breakdown Services (Subject to technical modifications) i 195

198 Special toolse 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 Order number: A Emergency shift at transmission, see page 126 Emergency shift at transmission, see page 126 3/4 R Adjusting screw for 3rd and 4th gears Order number: A Adjusting screw for reverse gear Order number: A Emergency shift at transmission, see page 126 Emergency shift at transmission, see page 126 GP Adjusting screw for high-speed splitter group Order number: A Vehicles with manual gearshift system (HPS) only 196 i Guidelines for Breakdown Services (Subject to technical modifications)

199 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 drive, see page 178). Special toolse 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 ; M 22x1.5 part no. A Adapter for test connections M 18 part no. A M 22 part no. A Pressure booster : for vehicles with brake system operating pressure of 8.5 bar 1 Guidelines for Breakdown Services (Subject to technical modifications) i 197