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Introduction of the New Truck GenerationThe New Actros (Model 963)

Daimler AG, GSP/OI, HPC R 822, D-70546 Stuttgart


Order No. 6517 1259 02 - HLI 000 000 02 77 Printed in Germany 06/11

Introduction of the New Truck


Generation
The New Actros (Model 963)
Introduction into Service Manual

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Mercedes-Benz Service

Introduction of the New Truck Generation


The New Actros (Model 963)

Daimler AG Technical Information and Workshop Equipment (GSP/OI) D-70546 Stuttgart, Germany

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Information and copyright


Product Portfolio
You can also find comprehensive information about our
complete product portfolio on our Internet portal:
Link:
http://aftersales.mercedes-benz.com

Questions and suggestions


If you have any questions or suggestions concerning this product, please write
to us.
Email:
customer.support@daimler.com
Fax:
+49-(0)18 05/0 10-79 78
or alternatively
Address: Daimler AG
GSP/OIS
HPC R822, W002
D-70546 Stuttgart, Germany

2011 by Daimler AG
This document, including all its parts, is protected by copyright.
Any further processing or use requires the previous written consent of
Daimler AG, Department GSP/OIS, HPC R822, W002, D-70546 Stuttgart.
This applies in particular to reproduction, distribution, alteration, translation,
microfilming and storage and/or processing in electronic systems, including
databases and online services.
Image no. of title image:
Order no. of this publication:

W00.01-1014-00
6517 1259 02 - HLI 000 000 02 77

09/11

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Contents
Preface

Overview
Vehicle concept

10

Model designation system

12

Model codes

13

Code system

14

Axle designation

16

Overall vehicle
Innovations

18

Vehicle models and product groups

21

Equipment

22

Maintenance
Maintenance system

28

Diagnosis

29

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Contents
Drive
Engine OM 471

30

Technical data

32

Engine cooling

34

Exhaust aftertreatment

37

Diesel particulate filter regeneration

40

Transmission
Transmission data

42

Mercedes PowerShift 3

44

Clutch

47

Power take-off

49

Brakes

Disk brake

50

Electronic brake control (EBS)

52

Secondary water retarder (SWR)

53

i Introduction of the New Truck Generation - The New Actros (Model 963)
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Contents
Chassis
Frame

56

Wheelbase

60

Suspension

61

Axles

66

Wheel configuration

70

Wheels and tires

71

Steering

73

Design
Cab

75

Cab mounting

81

Cab tilt mechanism

83

Seats and beds

84

Storage and stowage compartments

89

Instrument panel

90

Control and display concept

91

Instrument cluster

92

Multifunction steering wheel

94

Electronic ignition lock (EIS)

95

Transmitter key

96

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Contents
Networking
Overall network
On-board electrical system

98
104

Lights
Exterior lights

106

Interior lights

111

Safety
Active Brake Assist 2

112

Stability control assistant

114

Lane Keeping Assist

115

Roll control assistant

116

Tire pressure monitor

117

Driving assistance systems

Proximity Control Assist

120

Sensed fifth wheel coupling

121

Rain and light sensor (RLS)

122

Outside mirror with maneuvering position

123

i Introduction of the New Truck Generation - The New Actros (Model 963)
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Contents
Comfort
Heating and climate control

124

Audio and communications


Telematics

129

Special tools
Engine

137

Transmission

152

Annex
Abbreviations

158

Index

162

Introduction of the New Truck Generation - The New Actros (Model 963) i
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Contents

i Introduction of the New Truck Generation - The New Actros (Model 963)
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Preface
Dear Reader,
This Introduction into Service Manual presents the
new Actros (model 963).
This brochure is intended for the use of technical
personnel familiar with the service and maintenance
of Mercedes-Benz trucks. It is assumed here that the
reader is already familiar with the Mercedes-Benz
model series currently on the market.
In terms of the contents, the emphasis in this Introduction into Service Manual is on presenting new and
modified components and systems.
All of the data in this brochure correspond to the technical status as of the copy deadline in June 2011 and
may therefore differ from the current production
configuration.
We will publicize modifications and new features in the
relevant WIS documents only. Individual details in this
brochure may therefore differ from more up-to-date
versions published in WIS.
Daimler AG
Product Service Wrth, GSP/TTM
June 2011
i Note
The German versions of all notes and messages in
the multifunction display are shown because the
corresponding language versions are not available
at the time of the copy deadline.

i Note
Information about the vehicles and about operating the vehicle functions can also be found in the
interactive owner's manual on the internet at:
www.mercedes-benz.de/betriebsanleitung

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Overview

Vehicle concept
General
The newly developed medium-heavy and heavy
commercial vehicles will gradually replace the
previous truck product range of vehicles of 18 t
permissible gross vehicle weight and over. The new
vehicles are classified according to use into three
models for long-distance, distribution and construction applications. Each model has its own marked
appearance and a design which blends in harmoniously with the Mercedes-Benz truck product family.
The features characteristic of the long-distance
haulage model are high ride comfort, high economy
and excellent vehicle dynamics.

In addition to the aforementioned classification into


application areas by model, the vehicles are further
specified through "product groups" (PG). In the
case of long-distance haulage and distribution vehicles, these are Payload and Volume.
The Payload product group contains weight-optimized vehicles for payload-sensitive customers,
e.g. in the tank/silo segment. The Volume product
group comprises all low-frame variants with the
versions car transporter, low frame and Lowliner.

The new product range is based on a modular


system which allows customers to put together
their vehicles individually. Separating the models
into the three aforementioned application
segments makes it significantly easier for
customers to choose the right vehicle. Customers
no longer choose a basic vehicle which they then
have to adapt it to its purpose with suitable equipment. Instead, customers simply select the model
to obtain an optimally designed and equipped
vehicle.
Advantages of the modular system for the
customer:

One cab concept


Two engine concepts
Uniform electronic architecture
Uniform special equipment range
Standardized drive concept for all models

i Note
This Introduction into Service Manual only
describes the long-haul vehicles with market
launch in 09/2011:
4x2 and 6x2 platform vehicles and semitrailer
tractors (SZF) with long cab, (left-hand drive vehicles) with engine OM 471 (310, 330 and 375 kW)
in Euro V and Euro VI.

10

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Overview

Vehicle concept

W00-00-1054-00

The new Actros, semitrailer tractor with GigaSpace (F1J)

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11

Overview

Model designation system


This distinction is identified by the third digit of the
model designation number. The vehicle type, which
previously occupied the 3rd digit, moves one digit
to the rear but the familiar numbers have been
retained.

A new model designation system is being introduced with model 963. The six-digit model designation describes the properties of the basic model.
The future product range will be divided into two
basic concepts: road vehicles (Onroad) and
construction vehicles (Offroad).

The wheelbase is no longer part of the model designation number.

Comparison of previous and new model designation system


Previous model designation system
1st digit

2nd digit

3rd digit

4th and 5th digit

6th digit

Category

Model
Generation

Vehicle type

Wheel config.
Tonnage
Suspension

Wheelbase

01

Commercial vehicles

Actros

Semitrailer
tractor

4x2
20 t
Steel suspension

4200 mm

Example

New model designation system


1st digit

2nd digit

3rd digit

4th digit

5th and 6th digit

Category

Model
Generation

Usage

Vehicle type

Wheel config.
Tonnage
Suspension

03

Commercial
vehicles

Actros

Onroad

Semitrailer
tractor

4x2
18 t
Air suspension

Example

12

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The model codes remain largely unchanged.


Instead of the previous wheelbase specification, an
abbreviation of the model series and engine
displacement is shown.

Overview

Model codes

Example:

Rounded engine displacement


13 . . . . . . OM 471 (12,809 cm3)

Usage
FV . . . . . . Long-distance haulage
VV . . . . . . Distribution
BV . . . . . . Construction

Wheel configuration
Vehicle version
Engine power (hp)
Permissible gross vehicle weight in tons
W00.01-1013-00

Legend of vehicle version abbreviations:


None
A
AK
AS
B
K
L
LK
LS
S

Platform vehicle
All-wheel drive platform vehicle
All-wheel drive dumper vehicle
All-wheel drive semitrailer tractor
Concrete mixer
Dumper vehicle
Air-sprung platform vehicle
Air-sprung dumper vehicle
Air-sprung semitrailer tractor
Semitrailer tractor

nR
nRA
nRL
ENA
DNA
NLA
VLA

Low frame
Low frame/car transporter
Low frame/Lowliner
Single-tired trailing axle
Twin-tired trailing axle
Trailing axle
Leading axle

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13

Overview

Code system
The meaning of the code group starting with "D" has
been changed. Previously, this was only used for
roof codes. In future, this code group will be used
for "Cab interior" equipment. Group "F" now only
includes "Cab exterior" equipment as a result.

The special equipment codes still have three digits


but now have the sequence "letter - number letter".
The codes are made up of the installation location,
function and logical usage.

Communication equipment such as radio units is


now assigned to group "J".

Associated codes have the same digits. For


example, all front axles start with A1, rear axles with
A2 etc.

Group "S" no longer includes seats and beds, but


everything to do with safety e.g. stability control
assistant (S1D).

The number range "9" in the code groups is


reserved for preinstallations or omissions.

Structure of new code system


1st digit
Code group

2nd digit

3rd digit

Capital letter (A...Z)

Number (0...9)

Capital letter (A...Z)

Axles/suspension

Rear axle

Ring gear 440, hypoid, 13.0 t

Example

14

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Overview of code groups


A

Axles/suspension

Power take-offs

Brakes

Internal system control code

Chassis

Platform/dumper

Cab interior

Spring/crossmember/trailer hitch/fifth wheel


coupling

Electrical system

Wheels/spare wheel holder/wheel lifts

Cab exterior

Safety

Transmission/clutch

Unused

Distance between rear axle and fifth wheel


kingbolt

Unused

Internal code

Unused

Instrument/communication

Weight variants

Fuel system/exhaust system

Miscellaneous

Lighting system/lamps

Accessories

Engine

Internal system control code

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Overview

Code system

15

Overview

Axle designation
New designation of axles
With the introduction of the new Actros, all axles
have been given a new designation.
The basis for this is the Common Axle Platform
(CAP), whose aim is to standardize axle parameters
on a worldwide basis. This allows a greater number
of variants to be produced with a minimum number
of parts.

In future, axles will only be referred to using the new


naming convention. The previous designations
which included the axle model and axle model
series (e.g. HL6, VL4 etc.) have been discontinued.
Below you will find two examples of the new axle
designations, one for a "non-driven" axle and one
for a "driven" axle.

Non-driven axles

Model
Type

F. . . . . . . . Front axle
T. . . . . . . . Trailing axle
M . . . . . . . Leading axle

Load capacity

4.3 . . . . . . Axle load (4.3 t)


7.1 . . . . . . Axle load (7.1 t)
7.5 . . . . . . Axle load (7.5 t)
8 . . . . . . . Axle load (8.0 t)
8.5 . . . . . . Axle load (8.5 t)
9 . . . . . . . Axle load (9.0 t)
10 . . . . . . Axle load (10.0 t)

Version

None . . . . Steel suspension


A . . . . . . . Air suspension
L. . . . . . . . Raisable
S . . . . . . . Steerable

Brakes

C . . . . . . . Disk brake
S . . . . . . . Drum brake

Rim dia.

17.5. . . . . 17.5 inch (wheel head)


22.5. . . . . 22.5 inch (wheel head)
W00.01-1011-00

16

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Driven axles

Overview

Axle designation

Model
Type

R . . . . . . . Rear axle
RT . . . . . . Rear axle with through-drive
FD . . . . . . Front axle
FT . . . . . . Front axle with through-drive

Ring gear dia.

346 . . . . . Ring gear dia. (front axle)


360 . . . . . Ring gear dia. (front axle)
390 . . . . . Ring gear dia.
390T . . . . Ring gear dia. (2nd rear axle on tandem)
440 . . . . . Ring gear dia.
440E . . . . Ring gear dia. (optimized efficiency)
485 . . . . . Ring gear dia.
233P . . . . Ring gear dia. (planetary gears)
300P . . . . Ring gear dia. (planetary gears)

Load capacity

7.5 . . . . . Axle load (7.5 t)


8 . . . . . . . Axle load (8.0 t)
9 . . . . . . . Axle load (9.0 t)
9.5 . . . . . Axle load (9.5 t)
10 . . . . . . Axle load (10.0 t)
13 . . . . . . Axle load (13.0 t)
16 . . . . . . Axle load (16.0 t)

Version

None . . . . Steel suspension


A . . . . . . . Air suspension

Brake

C . . . . . . . Disk brake
S . . . . . . . Drum brake

Rim dia.

22.5 . . . . 22.5 inch (wheel head)


W00.01-1012-00

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17

Overall vehicle

Innovations
The new truck generation includes many innovations:
New vehicles in range:
20 t and 33 t air-sprung vehicles (platform,
dumper)
4-axle vehicles with 8x2/4 wheel configuration
(VLA and DNA, platform and dumper)
6x2 DNA with air suspension
6x2 SZF with single-tired trailing axle
All-wheel drive SZF with 18 t gross weight
4-axle vehicles with air-sprung rear axle as
platform and dumper
6x2/2 SZF with Hendrikson leading axle also
as LHD vehicle
Longer wheelbases available and previous
wheelbase gaps have been closed
Flexible overhang variants in 300 mm pattern,
bolted end crossmember
Further improvement in convenience for bodies through ex factory clearances on the frame,
e.g. for crane outriggers or units, special attaching parts on frame for platforms, dumpers and
concrete mixers and 3 switches instead of 1 for
current supply of bodies ex factory
Newly developed Mercedes-Benz six-cylinder
inline engines in Euro V or Euro VI, EEV
Cab range extended with new variants. The new
ergonomic driver cockpit and the entire interior
compartment are designed for maximum space
and comfort.
Wide and narrow cabs and all floor variants
can be combined with all engines - where technically possible
Improved aerodynamics and thus lower fuel
consumption through modular cooling air control system in the front module for demanddependent control of cooling air supply of cooling module

18

Engine cooling thermal management system


including a controlled coolant pump for demandbased provision of cooling output included as
standard on all 4x2 and 6x2 vehicles
Scope of soundproofing extended with multifunctional components for sound absorption,
reduced soiling and heat protection
Push-type clutch with pneumatic central clutch
release bearing (CPCA=Concentric Pneumatic
Clutch Actuator)
Transmission with automated gearshift system
controlled via multifunction control lever
Improved start-off comfort with crawl function instead of maneuvering mode
New drivetrain configuration with taller axle
ratios and increased torque in 12th gear (M0E)
for fuel economy
More flexible range of main and additional
tanks on both sides with various cross-sections
Intelligent compressed air supply with EAPU
and switchable compressor for all vehicles (previously only for 4x2 SZF)
Newly developed secondary water retarder
(B3H) with significant weight and space advantages over performance-optimized Voith
retarder (BA1)
Comprehensive comfort features in cab: new
beds, sound system, extended range of sockets
etc.
Digital operator's manual integrated in Comfort Bluetooth radio/navigation system (J2D)

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Aerodynamics
Various measures have been implemented to
improve aerodynamics:

Design of cab
Special aerodynamic roofs
Aerodynamically optimized air guides
Cooling air control in front module
Door extension
Aerodynamically optimized splash guard
Aerodynamically optimized underfloor

Overall vehicle

Innovations

Cab
The measures introduced to reduce the aerodynamic drag of the cab include:
The optimized bodyshell shape, tested in the
wind tunnel and on CAD systems
The optimized bumper
The more steeply inclined windshield
Front air guides

W88.00-1008-00

Cab aerodynamics
1
2
3
4

Front air guides


Side air guides
Roof air guides
Door extension

The drag-reducing design of the air guides provides


optimal air ducting to the sides of the vehicle front.
This has two advantages:
Low soiling of cab sides
Best-possible aerodynamics
Underfloor paneling
The aerodynamic side underfloor paneling deflects
the airstream under the vehicle. This reduces the
drag coefficient and fuel consumption. The side
underfloor paneling is available for all vehicles.
Door extensions
The paintable door extensions are made of plastic
and are bolted to the door. They cover the steps and
improve the airflow around the cab.
W00.00-1056-00

The new Actros in the wind tunnel

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19

Overall vehicle

Innovations
Cooling air control in front module
The modular cooling air control system in the front
module serves to control the supply of cooling air to
the engine compartment according to demand. The
flexible, fully automatic control system for cooling
air supply helps to improve the vehicle aerodynamics and thus lower fuel consumption. At low
outside temperatures, it also has a positive effect
on the engine's warming up characteristics through
the reduction in air flowing through the engine
compartment.

W20.20-109100

Cooling air control


1 Upper cooling air control system on vehicles with body
floor height 600
2 Upper cooling air control system on vehicles with body
floor height 765
3 Lower cooling air control system on vehicles without
Proximity Control Assist
4 Lower cooling air control system on vehicles with
Proximity Control Assist

i Note
The body floor height (ASH) designates the
distance from the lower edge of the floor panel to
the uppermost row of holes in the longitudinal
frame member. On vehicles with a flat cab floor,
the body floor height is always 765 mm, on vehicles with an engine tunnel it is always 600 mm.

20

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The new Actros will initially be launched with the


Volume product group. This provides the maximum
cargo area for transporting, e.g. whiteware such as
refrigerators or washing machines and materials
with low density such as excelsior, foams, insulation panels etc.

Overall vehicle

Vehicle models and product groups

W00.00-1057-00

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Overall vehicle

Equipment
The basic equipment is the equipment which is
installed in all vehicles as standard i.e. without
code. There is additional standard equipment
depending on the vehicle model/product group.

The packages which are controlled ex factory


combine safety or comfort equipment. The
following package variants are available for the
launch of the new model:

In the long-distance haulage model series, there is


also a choice of two lines - "Home-Line" and "StyleLine".

Safety Pack
Code

Basic

Classic

Top

Z0H

Z0I

Z0J

S1I

Proximity Control Assist

S1H

Lane Keeping Assist

S3A

Airbag, driver

S1F

Roll control assistant (only for platform mod.)

S1C

Active Brake Assist 2

B3H

Secondary water retarder

Classic

Top

Z0C

Z0D

Economy Pack
Code
S1Y

Tire pressure monitor

F5B

Clip-in air guides, with side deflectors

or
F5E

Rigid air guides, with side deflectors for Giga roof


or

F5I

Side deflectors without air guides

C8Z

Aerodynamic side paneling

or

22

C8R

Omission of aerodynamic side paneling


(with large tank)

E2J

Circuit breakers

B3H

Secondary water retarder

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Comfort Pack
Code

Basic

Classic

Top

Z0E

Z0F

Z0G

F8F

Comfort locking system

D4X

2-piece roller sun blind, electric, windshield

D5B

Ambiance illumination

J2K

Speakers, 2-way system

J2J

Sound system

D7F

Stowage compartment flaps above windshield,


one lockable

D7N

Flexible shelf system, for stowage compartment above windshield

F6R

Air horns, cab roof

Overall vehicle

Equipment

or
F6Q

Air horn

D4Z

Side roller sun blind, driver and passenger side

D0A

Leather steering wheel

or
D0D

Wood/leather steering wheel

D8M

Power tilting/sliding roof,


glass

J1E

Instrument cluster, 12.7 cm,


with additional indicators

D7K

Drawer below dash support

D6G

Automatic air conditioning

Y1X

Refrigerator in drawer, under bed

F0T

Illuminated Mercedes star

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Overall vehicle

Equipment
Climate Pack
Code

Z0K

D7A

Additional heat insulation

D6G

Automatic air conditioning

D6H

Stationary air conditioner

ADR Pack

Basic

Classic

Z0L

Z0M

Code
E2J

Circuit breakers

E5V

ADR model class FL including EX/II, EX/III and AT

or
E5W

ADR model class OX including AT


or

24

E5X

ADR model class AT

E5A

1 switch for other make body electrical system

E5Z

ADR accessories

B3H

Secondary water retarder

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Equipment

Code

Interior concept
Home-Line

Interior concept
Style-Line

D0B

D0C

Silver shadow
bead-blasted

Burred walnut veneer

Silver shadow
bead-blasted

Almond beige
Spotted

Black/silver velour

Burred walnut veneer

Silver shadow
bead-blasted

"Home-Line"

"Style-Line"

Deep dark gray

Silver shadow

Burred walnut veneer

Silver shadow
bead-blasted

Burred walnut veneer

Silver shadow
bead-blasted

Overall vehicle

Equipment

Interior
Air vent surrounds

Inside door closing handle

Door mirrors

Caps around multifunction buttons (steering wheel)

Lettering on stowage compartment above windshield


Left/right multifunction control lever
Platform/balcony trim strip
Platform/balcony trim strip, hand brake valve

Passenger-side instrument panel trim strip

12.7 cm instrument cluster with additional indicators


(J1E)
Velour tunnel center inserts
Hand brake valve leather boot
Step rail (on one floor)

= Included

With white scaling


Almond beige

Anthracite

Die-cast aluminum

= Not included

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Overall vehicle

Equipment
Equipment

Interior concept
Home-Line

Interior concept
Style-Line

D0B

D0C

Chrome badge on sun visor

Chrome-plated mirror trim

Leather steering wheel (D0A)

Ambiance illumination (D5B)

Painted outside mirrors (Z7L)

Front fog lamps, LED daytime running lights (L1I)

Illuminated Mercedes star (F0T)

Code
Exterior

Further special equipment

= Included

26

= Not included

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"Home-Line" interior concept

W68.00-1014-00

"Style-Line" interior concept

W68.00-1015-00

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Overall vehicle

Equipment

27

Maintenance

Maintenance system
The maintenance intervals are determined by the
maintenance system (MS) control unit according to
the vehicle usage. The remaining time or remaining
distance until the next service is due is shown on
the multifunction display.
Due to technical developments, the maintenance
intervals of certain components and major assemblies have been extended. At the same time, emphasis was placed on ease of maintenance and repair right from the design stage of new products.
This is shown, for example, by the good accessibility to maintenance points and reduced removal/installation times.
The maintenance system is included as standard on
all vehicles and takes the form of a software component of the central gateway control unit (CGW).
The following components are monitored by sensors (depending on vehicle version):

28

Engine
Transmission
Transfer case
Retarder
Front axle (on all-wheel drive vehicles)
Rear axle (RA) (preinstallation for 2nd rear axle
is available but no temperature sensor is
installed currently)
Air filter
Brake linings (up to 5 axles)
Time-based servicing scheme (everything which
is serviced once a year)
Universal components (for body manufacturers)
Power take-off 1-3 (not assigned ex factory)
Fuel filter
Diesel particulate filter (DPF)

For the engine, transmission and axles, sensing


takes place via the oil temperature. A higher oil
temperature indicates a higher load and the defined
"service life" of the major assembly expires more
quickly. Based on the current load data, the maintenance system calculates the remaining time until
the next service is due.
Since the quality of oil used also affects the service
life of a major assembly, this can be set to 3 stages.
For engine oil, the viscosity of the oil used is also
relevant.
The fuel grade also influences the service life, which
is why its sulfur content can be set in the menu.
0 0.05 % sulfur content = factor 1
0.05 0.1 % sulfur content = factor 0.5
> 0.1 % sulfur content = factor 0.3
Roughly 2 weeks before a service is due, the driver
is informed about this via a pop-up message when
the ignition is switched on. The next warning stage
appears with the message "Service immediately".
All of the displayed messages are stored in the
memory so that, in the event of complaints, it is
possible to determine when each message was displayed.

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Diagnosis

On-Board Diagnosis (OBD)

The diagnosis functions of the control units are primarily intended to ensure that the corresponding
systems operate properly. This takes place through
ongoing checking of whether the sensors connected to a control unit supply plausible values. The diagnostic data can also be used for troubleshooting.

OBD is used to monitor and diagnose all systems


which affect exhaust emissions. It is a legal requirement. Malfunctions and faults which occur are displayed to the driver via an indicator lamp and stored
in the fault memory. These can be read out using
Star Diagnosis.

The UDS (Unified Diagnostic-Services) diagnosis


protocol, which is also used in the passenger car
sector, is used for data transfer purposes.

The stricter regulations of OBD 2 apply to the Euro


VI standard.

Compared to the predecessor model, the diagnosis


routines for service have been significantly optimized. This is particularly noticeable in the speed of
communication with control units. The diagnostic
CAN operates at 500 kBaud and multiple control
units can transmit and receive simultaneously.

Maintenance

Diagnosis

The OBD-NOx-Control system monitors, for example, the quantity of nitrogen oxide (NOx) and particulate mass (PM) emissions. If the limits are exceeded, the system informs the driver and takes action
e.g. actuation of the MIL (Malfunction Indicator
Lamp) or, in the most extreme case, torque reduction.

When a control unit is flashed, communication between control units is interrupted in order to free up
the CAN line. This shortens the flashing time from
approx. 30 min to approx. 3 min.
Faults which occur can be read out on the instrument cluster. The advantage of this is that the driver
can read out the faults and inform the workshop in
advance about which faults are occurring.

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29

Drive

Engine OM 471
General
Engine OM 471 represents the first time a 6cylinder inline engine with double overhead
camshaft (DOHC) has been used in a commercial
vehicle.
The two camshafts are driven by a gear drive on the
output side of the engine. This significantly reduces
noise emissions.
Engine OM 471 is available in four power categories
ranging between 310 and 375 kW.
The excellent characteristics of the engines, in
particular their low fuel consumption in relation to
their high power, have been achieved with a range
of technical innovations:

The new injection system (APCRS=Amplified


Pressure Common Rail System) represents the
first time a Common Rail system with pressure
amplification has been used in a commercial
vehicle. This system reduces the quantity of fuel
required for combustion to a minimum.
The engine braking system has been completely
redeveloped and impresses with even greater
braking power.
The cooled and controlled exhaust gas recirculation system (AGR), the diesel particulate filter
(DPF) and a modified crankcase ventilation
system ensure that the system will also comply
with future emissions regulations.

W01.10-1091-00

Engine OM 471 Euro VI

30

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Drive

Engine OM 471

W01.10-1092-00

Overview of engine OM 471


1 Rail
2 Diesel fuel metering unit (for regeneration of diesel
particulate filter)
3 Oil/coolant module with coolant pump
4 Fuel filter module
5 Compressor
6 Power steering pump
7 Oil separator of crankcase ventilation system
8 Turbocharger
9 Exhaust gas recirculation cooler

G2 Alternator
M1 Starter
A
B

Left ("cold") side of engine


Right ("hot") side of engine

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31

Drive

Technical data

Displacement

Unit

OM 471

cm3

12809

Cylinder number/arrangement

6/inline

Valve timing

DOHC

Number of valves per cylinder (intake/exhaust)

2/2

Idle speed

rpm

560

Power

kW

310 (M3A)
330 (M3B)
350 (M3C)
375 (M3D)

Torque

Nm

2100 (M3A)
2200 (M3B)
2300 (M3C)
2500 (M3D)

Compression ratio

32

17.3

Stroke

mm

156

Piston diameter

mm

132

Total piston height

mm

113.5

Compression stroke

mm

75

Piston shaft length

mm

56.5

Connecting rod length

mm

268

Cylinder diameter

mm

132

Cylinder spacing

mm

165

Rail pressure (max.)

bar

900

Weight (approx.)

kg

1200

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Drive

Technical data
Performance graphs

W01.00-1081-00

W01.00-1083-00

a OM 471, 310 kW (M3A)

c OM 471, 350 kW (M3C)

b OM 471, 330 kW (M3B)

d OM 471, 375 kW (M3D)

M
P
n

Torque
Output
Rpm

i Note

i Note

For further information, see "Introduction into


Service Manual for Engine 471 and exhaust aftertreatment",
order number 6517 1260 02 - HLI 000 000 02 82.

For the three engine variants M3A, M3B and M3C,


the torque can be increased by 100 Nm (M3A) or
200 Nm (M3B and M3C) in combination with code
(M0E).

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33

Drive

Engine cooling
The vehicle cooling system is designed as a "cooling
module" with separate expansion reservoir.
The cooling module consists of the following
components:

Condenser (only with air conditioning)


Charge air cooler
Radiator
Fan shroud
Expansion reservoir

Vehicles with secondary water retarder are


equipped with a 1-chamber expansion reservoir
with pressure relief valve, which is supplied with
pressure externally from the auxiliary consumer
circuit.
The multifunction display of the instrument cluster
visually displays whether the coolant level is OK,
too high or too low. If the coolant temperature is too
high, an acoustic warning is also issued.

Vehicles without secondary water retarder are


equipped with a 2-chamber expansion reservoir for
rapid pressure buildup. Here, the smaller chamber
is protected by a pressure relief valve leading to the
larger chamber, while the pressure relief valve of
the 2nd chamber can blow off to the outside if
necessary.

Coolant
With the introduction of the new Actros, the
previous coolant G48 (green/blue) has been
replaced with coolant G40 (red). This has the
following advantages:
Better performance compared to G48 due to
fewer deposits in the cooling system
Better heat dissipation
More environmentally friendly because it no
longer includes any ecologically harmful borax
components
Mixing the two coolants is not permitted. A mixture
results in rust-brown discoloration. This can potentially cause problems.
As a result, the G48 must be drained off first before
filling the system with G40. Low residual quantities
(1 % -3 %) of G48 in the cooling system only result
in insignificant discoloration and are safe.

W20.20-1092-00

Cooling module
1
2
3
4
5

Condenser
Charge air cooler
Radiator
Fan shroud
2-chamber expansion reservoir
(without secondary water retarder)
6 1-chamber expansion reservoir
(with secondary water retarder)

34

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Drive

Engine cooling
Engine cooling thermal management
The engine cooling thermal management system
optimizes the efficiency of the engine and thus
reduces fuel consumption. This is achieved by deliberately influencing the coolant temperature and by
actuating the following components according to
demand:
Coolant pump
Fan clutch
By regulating the coolant pump, the coolant
throughput in the engine is reduced to the level
required by the respective operating condition.
In addition, the cooling air throughput of the engine
radiator is regulated via the fan clutch depending on
the operating condition.

Cooling air control


When the radiator shutters are open, the cooling air
can flow through the radiator and thus the entire
engine compartment and frame. This results in
increased aerodynamic drag, which has an effect on
fuel consumption.
As of a parameterizable speed, the slats of the radiator shutters are closed in order to keep the drag
coefficient low. During driving operation, the
system regulates according to demand. Actuation
is carried out by actuator motors.
When the vehicle is parked, the radiator shutters
are opened to prevent damage, jamming and icing
up at low outside temperatures in the closed state.
The position of the slats can be queried via the position of the stepper motors and malfunctions are
displayed via appropriate messages on the multifunction display. In the event of a malfunction, the
radiator shutters are opened to ensure a supply of
cooling air (failsafe).

W20.20-1086-00

Upper cooling air control system (with ASH 600)


1 Radiator shutters
2 Lever
3 Actuator motor
A Radiator shutters closed
B Radiator shutters open

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35

Drive

Engine cooling
Controlled coolant pump (M7T)
The main component of the thermal management
system is the controlled coolant pump. This
features an electric viscous coupling which allows
the pump element to be engaged and disengaged.
In terms of design, controlled and uncontrolled
coolant pumps differ through their different belt
pulley diameters and the coupling element.
The coolant pump is mounted on the left-hand side
of the engine and is driven by the poly-V belt.

Safety/limp-home mode
The controlled coolant pump is designed as a failsafe component. This means that, in the event of a
malfunction, the operational safety of the vehicle is
maintained and no consequential damage is
expected.
Emergency running characteristics:
In the event of electrical faults (e.g. cable break,
short circuit), the pump is designed to automatically operate at maximum output.

W20.10-1070-00

Oil/coolant module with controlled coolant pump

36

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General

System monitoring

In order to comply with current and future exhaust


emission limits, the vehicle also features an exhaust
aftertreatment system consisting of an SCR catalytic converter (Selective Catalytic Reduction) and
diesel particulate filter (DPF) in addition to the inengine exhaust gas recirculation system.

Multiple pressure, temperature and NOx sensors


are used to monitor the function of the system,
which is a legal requirement. These continuously
monitor the quality of the exhaust treatment.

All of the components are housed in one housing,


the exhaust aftertreatment unit.
Exhaust aftertreatment in the exhaust aftertreatment unit takes place in two stages:
First stage:
oxidation catalytic converter and diesel particulate
filter
Second stage:
SCR catalytic converter

Drive

Exhaust aftertreatment

Furthermore, every detected fault is stored in the


fault memory of On-Board Diagnosis (OBD2). If the
legally stipulated limits are exceeded, the engine
power is reduced in stages.
The NOx sensor is the central component of the
exhaust aftertreatment system. It continuously
checks the proportion of nitrogen oxides in the
exhaust during driving operation. Based on this
information, the required quantity of AdBlue is
calculated.

Euro V
In contrast to the Euro VI engine version, there is no
diesel particulate filter. There are only 2 instead of
5 temperature sensors and only 1 NOx sensor
instead of 2. All of the exhaust pressure sensors are
omitted because these are only used to determine
the charge level of the diesel particulate filter on
Euro VI engines. There are also minor changes in
the location of the components.

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37

Drive

Exhaust aftertreatment

W49.20-1016-00

Location of exhaust aftertreatment components

W49.20-1015-00

Exhaust aftertreatment unit (schematic) for Euro VI


1
2
3
4
5
6
7
8
9

38

Exhaust aftertreatment unit


AdBlue tank
Exhaust aftertreatment (ACM) control unit
Pump module
AdBlue metering device
Exhaust temperature sensor
Exhaust pressure sensor
NOx sensor
AdBlue injection

DOC Diesel oxidation catalytic converter


DPF Diesel particulate filter
SCR SCR catalytic converter
A
B

Exhaust gases from engine


Exhaust gases downstream of exhaust aftertreatment unit

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Drive

Exhaust aftertreatment
Exhaust aftertreatment unit (Euro VI)

W49.20-1014-00

a Exhaust gases from engine


b Exhaust gases downstream of diesel particulate
filter/diesel oxidation catalytic converter
c Exhaust gases downstream of SCR catalytic
converter

D Diesel particulate filter/diesel oxidation catalytic


converter
S SCR catalytic converter
F Direction of travel

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39

Drive

Diesel particulate filter regeneration


Automatic regeneration
Active regeneration normally takes place automatically roughly every 8000 km. The exact time is
determined by evaluating the two pressure sensors
of the exhaust aftertreatment control unit (ACM).
Regeneration can be suppressed by the driver by
pressing the "Stop regeneration" button (1b) e.g. to
prevent increased exhaust temperatures during
transportation of hazardous goods (GGVS).
Manual regeneration
Furthermore, manual activation of regeneration by
the driver is possible as soon as the message that
regeneration is required is shown on the multifunction display.

40

W54.25-1194-00

1
a
b
c

Regeneration button
Start
Stop
Regeneration stopped indicator lamp

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Particulate
filter full

Particulate
filter full

High particulate
filter fill level

Display

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Service required

Reduced power

Start regeneration
immediately

Start regeneration

No action required: active regeneration in progress. Pay attention to high


exhaust temperatures, comparable to those with wide open throttle, at the
exhaust pipes. Do not interrupt regeneration if possible.

"DPF regeneration"

Action required within 30 minutes: perform an extended trip with significant


engine load (freeway, mountain driving etc.) or carry out manual regeneration
with vehicle at standstill.
(Duration approx. 30 minutes)

Need for immediate action: perform manual regeneration with vehicle at


standstill.
(Duration approx. 30 minutes)

Need for immediate action: visit workshop and have DPF cleaned or
replaced. It is only possible to drive to the next workshop under reduced
power. Regeneration is no longer possible.

"Particulate filter full"

"Particulate filter full"


+
"Reduced power"

"Particulate filter full"


+
"Service required"

"High particulate filter fill Action required within the next 4 to 5 hours: perform an extended trip with
level"
significant engine load (freeway, mountain driving etc.) or carry out manual
regeneration.
(Duration approx. 30 minutes)

What must be done?

Message

Diesel particulate filter regeneration

Introduction of the New Truck Generation - The New Actros (Model 963) i

Drive

Diesel particulate filter regeneration

41

Transmission

Transmission data
The following further developed transmissions are
used on the new Actros:
Direct drive transmission G211-12 (G2B)
Direct drive transmission G281-12 (G2E)
Overdrive transmission G330-12 (G2F)
These transmissions are equipped with the
Mercedes PowerShift 3 (G5G) automated gearshift
system as standard.
The following new features have been introduced
with the automated gearshift system:
Improved shifting strategy with shorter shifting
times due to better engine coordination
Omission of "maneuvering mode", replaced by
the new "crawler mode" function"
Additional "Power" (G0V) or "Economy" (G0U)
transmission modes available as special
equipment
Transmission control via the new right
multifunction control lever
Omission of the individual gear module, gate
module and clutch actuator components,
replaced by a common unit in the form of the
transmission positioner

W26.00-1031-00

A5
Transmission control unit (TCM)
Y900 Transmission positioner

The transmission positioner combines the following


components in one assembly:
Transmission control unit (TCM)
Gear and gate cylinders
Solenoid valves for clutch, countershaft brake,
splitter group, gear cylinder, gate cylinder and
range group
Splitter group, gear cylinder and gate cylinder
position sensor module

42

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Transmission ratios
Designation

G211-12

G281-12

G330-12

G2B

G2E

G2F

715.352

715.371

715.381

1st gear

14.93

14.93

11.64

2nd gear

11.67

11.64

9.02

3rd gear

9.02

9.02

7.04

4th gear

7.06

7.04

5.45

5th gear

5.63

5.64

4.40

6th gear

4.40

4.40

3.41

7th gear

3.39

3.39

2.65

8th gear

2.65

2.65

2.05

9th gear

2.05

2.05

1.60

10th gear

1.60

1.60

1.24

11th gear

1.28

1.28

1.00

12th gear

1.00

1.00

0.78

1st reverse gear

14.93

16.39

12.77

2nd reverse gear

11.67

12.77

9.90

3rd reverse gear

3.39

3.72

2.90

4th reverse gear

3.65

2.90

2.25

Code
Model designation

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Transmission

Transmission data

43

Transmission

Mercedes PowerShift 3
Mercedes PowerShift 3

Transmission modes

Mercedes-PowerShift 3 features 12 forward gears


and 4 reverse gears. The transmission control
system controls clutch actuation during driving
operation e.g. during start-off, maneuvering, gear
changing and stopping.

Automatic
In the Automatic transmission mode, the transmission control system shifts the gears depending on

Engine speed
Accelerator pedal position
Operating state of permanent brake
Load condition of vehicle
Road surface terrain

In addition, the automatically activated EcoRoll and


crawl driving functions can be switched on and off
via the "Vehicle systems" menu window in the
"Settings" menu.
Depending on the transmission version, the shift
program is designed for:
A power - performance-oriented, dynamic
driving operation with high rpms
A economy - fuel-efficient driving operation
Manual transmission mode
Right multifunction control lever
1 Transmission position switch (D/N/R)
2 Transmission mode button
3 Engine brake and retarder control

44

W54.25-1178-00

In manual transmission mode, the driver initiates


the shift operations. Gearshift recommendations
are displayed on the multifunction display.

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Overview of transmission modes


Transmission mode

Economy

Power

Automatic

Manual

In combination with
Power transmission mode (G0V)

In combination with
Economy transmission mode (G0U)

Kickdown

EcoRoll can be deactivated

85.0

89.8

89.8

Softcruise

Standard

Standard

Maximum speed [km/h]

Cruise control
= Available

Transmission

Mercedes PowerShift 3

= Not available

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45

Transmission

Mercedes PowerShift 3
Crawl function
The crawl function allows the vehicle to automatically start crawling when the service brake is
released and to continue crawling when the accelerator pedal is not actuated.
The crawl function is automatically switched on
after the engine is started and can be switched on
or off via the "Vehicle systems" menu window in the
"Settings" menu.
The crawl function replaces the "Maneuvering
mode" of the predecessor model.
Gear indicator on multifunction display
1
2
3

W54.32-1023-00

Gear range and/or engaged gear


Gearshift recommendation or preselected gear
(flashing)
Transmission mode

Possible displays:
1-12
1st to 12th gear
N
Neutral
N1
Low-speed splitter group
N2
High-speed splitter group
E
Neutral position for EcoRoll
R1 - R4
1st to 4th reverse gear
A
Automatic transmission mode
A economy Automatic transmission mode with operationspecific shift program
A power
Automatic transmission mode with operationspecific shift program
M
Manual transmission mode

Rocking the vehicle free


With the vehicle rocking function, the vehicle can be
rocked out of a depression in the ground/road
surface. The transmission control system switches
automatically to manual transmission mode.
If the accelerator pedal is released when the vehicle
rocking function is activated, the clutch disengages
immediately and vehicle rolls back. If the accelerator pedal is actuated again, the clutching engages
and the vehicle moves forward.
The vehicle rocking function is switched on and off
by pressing the vehicle rocking button in the
modular switch panel (MSF) control unit.

EcoRoll
EcoRoll supports a fuel-efficient driving style. If the
accelerator pedal is not operated during driving
operation, the transmission control system shifts to
neutral depending on the driving situation. The
multifunction display shows "E". EcoRoll takes
effect as of a speed of approx. 35 km/h.

W54.25-1179-00

Vehicle rocking button

46

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The clutch is installed directly on the flywheel and


serves to interrupt the power flow between the
engine and transmission to allow the gears to be
shifted. On vehicles with Mercedes PowerShift 3
(G5G), the clutch is a push-type clutch operated by
the pneumatic central clutch release bearing.

Transmission

Clutch

In order to allow greater mileages with the same


contact force of the clutch, clutch plates with
thicker clutch linings and clutch pressure plates
with integrated automatic self adjustment are
installed.
The self adjustment mechanism of the clutch pressure plate compensates for the wear travel of the
clutch linings and keeps the contact force constant
during 90 % of the clutch service life.
The self adjustment mechanism continuously registers the decrease in clutch lining thickness and
compensates for the gap by turning the adjusting
ring (3).

1
2
3
4
5
6

Pressure plate
Coil spring
Adjusting ring
Coil spring
Slider
Leaf spring

W25.10-1072-00

i Note
The adjusting mechanism cannot be reset manually and, in the event of repair, the clutch pressure
plate must always be replaced together with the
clutch plate.

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47

Transmission

Clutch
Pneumatic central clutch release bearing
The central clutch release bearing (1) is located on
the transmission input shaft of the manual transmission and is rigidly bolted to the front of the
transmission housing.
Actuation of the pneumatic central clutch release
bearing (1) is carried out by the transmission
control unit (TCM) and via the solenoid valves integrated in the transmission positioner.
When the clutch is operated, the piston (4) of the
central clutch release bearing (1) is pressurized
with compressed air via the bore (arrow) and
pushed forwards on the guide sleeve (8). The
release bearing (2) thus presses against the disk
springs of the clutch and actuates them. The inner
seal of the central clutch release bearing (1) takes
the form of two sealing rings (6 and 7).

1
2
3

Central clutch release bearing


Release bearing
Transmission input shaft

B503

Clutch travel sensor

1
2
4
5
6
7
8
9

Central clutch release bearing


Release bearing
Piston
Preload spring
Sealing ring
Sealing ring
Guide sleeve
Electrical connector

B503
Arrow

Clutch travel sensor


Air supply bore

W25.20-1116-00

The preload spring (5) ensures that the release


bearing (2) is always under minimal load when the
clutch is not operated in order to avoid bearingrelated noises. The transmission control unit (TCM)
inductively determines the position of the central
clutch release bearing (1) via the clutch travel
sensor (B503) installed on the central clutch
release bearing (1).

48

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W25.20-1117-00

Thanks to a very comprehensive range of power


take-offs (PTO) installed in various positions and
with different gear ratios and rotation directions including in combination with a secondary water
retarder (B3H) - almost all customer requirements
can be met by the new product range.

Transmission

Power take-off

Power take-offs with flange are equipped with a


120 mm diameter, 8-hole flange connection as
standard. Also available as special equipment:
100 mm diameter, 6-hole (N9Y).
For applications with continuous PTO operation, a
transmission cooling system (N6Z) is available. The
oil/air cooler with 7 kW cooling output is located
under the entrance on the passenger side. This
location saves space on the frame.

W27.55-1000-00

Transmission oil cooling


1 Engine cooling system cooling module
2 Transmission cooler

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49

Brakes

Disk brake
The SL7 and SM7 disk brakes are installed in the
new Actros.
The SL7 disc brake is installed on the rear axle and
the SM7 disk brake is installed on the front axle.
These new disk brakes are further developed
versions of the previous SN7 disk brake.

The procedures for removing and installing the


brake caliper and brake disk on the SL7 and SM7
disk brakes are identical to those for the previous
SN7 disk brake.
A comparison of the technical data shows the basic
differences between the previous SN7 disk brake
and the new SL7 and SM7 disk brakes.

Unit

SN7

SL7

SM7

Weight

kg

41.7

37.6

39.8

Braking torque

Nm

27

25

30

Lining width

mm

247.6

207.6

244.6

Lining area

cm2

184

159.5

186

W42.10-1313-00

Brakes
1 Front axle brake caliper ("12 o'clock" position)

50

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Modifications

Brakes

Disk brake

Brake lining (2)


Holddown spring (1) with cap on each brake
lining (2)
Inner brake lining with partially integrated thrust
pieces (3)
Bottom edge of brake lining with chamfer
(arrow)
Protection against component swapping i.e.
only these brake linings can be installed in the
new disk brake

W42.10-1306-00

Brake caliper support (4)

Parking brake

Installed on axle in the "12 o'clock" position


(only disk brake SM7)
Smaller dimensions (only disk brake SL7)
Progressive transmission characteristic through
modified brake lever
Reduced weight
Modified brake adjuster
Protected against component swapping i.e. only
brake linings for the new disk brake can be
installed.

The parking brake is actuated via the hand brake


valve in the instrument panel and acts on the
spring-loaded actuators of the rear axle as standard. If the parking brake is not actuated when the
door is opened and the transmission is in neutral, a
warning buzzer sounds.

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51

Brakes

Electronic brake control (EBS)


The electronic brake control (EBS) system (B1B) is
an electronic control system with ABS and ASR
which acts on the pneumatic brake system and is
standard equipment on all vehicles.
EBS functions

52

Anti-lock braking system (ABS)


Acceleration skid control (ASR)
Stability control assistant
Stability optimization: by limiting the FA brake
pressure, the low rear axle load of solo semitrailer tractors is compensated for and the
vehicle remains more stable during braking.
Permanent brake integration: when the service
brake is actuated, the permanent brakes
installed in the vehicle are automatically activated via CAN connections if the road surface
allows (as detected by the wheel speed
sensors).
Brake Assist System: emergency situations are
reliably detected by, for example, the speed of
pedal actuation and a lack of braking power
(because the brake pedal is not depressed
hard/far enough) is automatically compensated
for.
Rpm sensing and tire compensation: during
driving operation, differences in the actual tire
sizes are automatically compensated for.
Hill holder: standard equipment of EBS, activated via a locking push button switch in the
switch panel. When the vehicle is braked to a
standstill, the brake pressure is maintained as
long as the brake or accelerator pedal is at least
slightly depressed.

In the event of a total electrical failure, all axles of


the tractor and trailer can be braked via the redundant pneumatic brake circuits.
In order to warn following vehicles and thus
improve road safety, the hazard warning system is
actuated with an increased flashing frequency as of
a certain level of deceleration. In this case, it does
not matter whether the brake application was initiated by the driver or by one of the driving assistance systems.
Service brake
The central component is the electronic brake
control (EBS) control unit which is installed in the
electronics compartment in the cab. This determines the desired deceleration based on the signal
from the brake value sensor and, if applicable, the
requirements of external systems.
Communication takes place via CAN connections.
Pressure limitation for redundancy cases (ratio
1:1.5) for the rear axle is now integrated in the
brake value sensor. A new part of the system
network is a 1-channel axle modulator for regulating the front axle. This also incorporates a solenoid valve for directional switching of the redundant
pressure.
The brake pressure for the axles is regulated by the
front axle and rear axle axle modulators, whereby
the front axle is only actuated by one circuit. Here,
individual control takes place via the downstream
ABS valves on each side of the axle.
The axle modulator for the rear axle has a separate
channel for each side.

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Brakes

Secondary water retarder (SWR)

W43.30-1306-00

Secondary water retarder


1
2
3

Coolant manifold (inlet)


Coolant manifold (outlet)
Relief valve

A11 Retarder control unit (RCM)


B933 Coolant temperature sensor

The secondary water retarder is located on the left


of the vehicle (in the direction of travel) on the
transmission next to the output flange and is
connected to the transmission via a gear.

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53

Brakes

Secondary water retarder (SWR)


General
The secondary water retarder (SWR) available as
special equipment (B3H) is a wear-free hydrodynamic permanent brake whereby the flow energy of
a fluid medium is used to brake the vehicle.
In principle, its design corresponds to that of a
torque converter. The stator (A) is secured against
turning relative to the rotor and stator frame. The
rotor (B) is connected to the drivetrain. The fluid
brake medium circulates (C) between the turning
rotor and the fixed stator (A). This generates a
braking torque on the rotor (B) which acts on the
vehicle drivetrain through a pair of gears. Due to the
gear ratio, the retarder achieves high braking
torques right down to low rpm ranges.

The SWR builds upon the functional principle of the


familiar performance-optimized Voith retarder
(BA1). However, instead of retarder oil, the SWR
uses the coolant of the engine cooling circuit as a
braking medium.
This innovative development optimizes the previous
retarder design with increased braking effect
through the following features:
Weight reduction of approx. 30 kg
Maximum braking power n = 3650 Nm
(VR115HV: n = 3500 Nm)
Reduction of installation space by approx. 50 %
due to omission of oil cooler
Reduction in maintenance costs due lack of oil
change requirement
Reduction in variants

W43.30-1304-00

54

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Function requirements
Anti-lock braking system (ABS), acceleration skid
control (ASR) and stability control assistant are not
performing control interventions.

Function sequence
The retarder can be actuated both by the driver via
the right multifunction control lever and by the
following driver assistance systems:
Cruise control
Proximity Control Assist (S1l)
The braking request by the driver is issued via the
permanent brake switch on the right multifunction
control lever. The driver can preselect the intensity
of the SWR braking effect.

The drive control (CPC) control unit then transmits


a corresponding request via drivetrain CAN to the
retarder control unit (RCM).

Brakes

Secondary water retarder (SWR)

In addition to the braking request by the drive


control (CPC) control unit, the retarder control unit
(RCM) also evaluates further information:

Vehicle speed
Coolant pump rpm
Coolant temperature
Transmission output speed
Engine speed

Based on this information, the retarder control unit


(RCM) calculates a characteristics map which
corresponds to the required braking torque and is
used to regulate the pneumatic actuating pressure
at the SWR.

In addition, the SWR can be activated through


system-initiated braking torque requests from the
cruise control or Proximity Control Assist driving
assistance systems.
Both driver-initiated and system-initiated braking
torque requests are evaluated by the drive control
(CPC) control unit. The drive control (CPC) control
unit calculates the required intensity of SWR
braking, also taking the engine braking power into
account.

i Note
Further information about the secondary water
retarder can be found in the Actros electronic
systems function description,
Order no. 6517 1261 02 - HLI 000 000 02 89

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55

Chassis

Frame
Frame concept
The frame concept incorporates a wheelbase pattern of 300 mm. The range extends from 2550 mm
(C1B) as the smallest wheelbase on 6x2/2 semitrailer tractors up to the largest wheelbase of
6700 mm (C3V), which is available as special equipment for 4x2 platform vehicles.
The vehicles have a front vehicle overhang of
1400 mm (= 650 mm front frame overhang), which
provides for optimal entry and offers sufficient
installation space in the wheel well for tires up to
315/80 R 22.5 without snow chains.
Starting with a uniform frame track width of
900 mm in the front area (outer edge of longitudinal
frame members), there are 2 track width versions
for the rear area to accommodate air-sprung and
steel-sprung vehicles: air-sprung vehicles have a
frame track width of 834 mm whereas steel-sprung
vehicles have a frame track width of 744 mm
(based on inner edges of longitudinal frame members).

A standard rear overhang is defined for every model


designation/wheelbase combination and all other
possible rear overhangs can be ordered as special
equipment for the specific model designation with a
code. Apart from a few exceptions, the rear frame
overhangs are also available in a pattern of 300 mm
stages up to a maximum overhang of 3900 mm,
whereby the maximum available overhang depends
on the respective model designation and wheelbase. The range extends from 750 mm up to
3900 mm (C0A to C9I). The maximum permissible
rear overhang remains unchanged at 65 % of the
wheelbase on 2-axle vehicles and 70 % of the technical wheelbase on 3-axle vehicles.

There is a new concept for describing the rear overhangs: previously, an extension of the standard rear
overhang for 2 and 3-axle vehicles was possible
with a single code for each vehicle but on the new
Actros every possible rear overhang length has its
own code.

W00.10-1171-00

A Frame overhangs (mm)


B End crossmember positions (mm)

56

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Chassis

Frame

W31.00-1079-00

Frame of semitrailer tractor with integral rear end (LS 4x2)


1
2
3
4
5
6
7
8

Front crossmember
Front spring bracket crossmember
Crossmember below transmission
Frame reinforcement
Crossmember downstream of transmission
Drive axle tubular crossmember
End crossmember
Longitudinal member

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57

Chassis

Frame
Frame track widths
Frame track width with air suspension
Front width 900 mm
Rear width 834 mm
"Stiff" design and reinforced struts ensure better
road holding

W31.00-1080-00

Frame track width with steel suspension


Front width 900 mm
Rear width 744 mm
"Soft" design

W31.00-1081-00

58

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Overview of frame heights


Suspension

Vehicle model

Frame height, loaded [mm]


Front axle

Standard frame
Steel/air

Chassis

Frame

Rear axle
Tires 315/80

Standard

935

980

C5Y

935

955

Standard

980

980

SZF 4x2

955

980

C5Y

955

955

Air/air

Low frame

Tires FA 355/50 and RA 295/60


Platform

845

845

SZF 4x2

830

830

Lowliner

800

792

Air/air

C5Y = Frame height lowered by 25 mm

Overview of coupling point heights


Vehicle

Model designation

Tires

Fifth wheel coupling height [mm]

315/70 R22.5
4x2 LS

963.403

With C5Y

4x2 LSNR

4x2 LL

963.404

963.406

495/45 R22.5
315/80 R22.5

Coupling point
height [mm]
1113

165

1120
1145

315/70 R22.5

1088

315/60 R22.5

990

295/60 R22.5

145

975

295/55 R22.5

961

295/55 R22.5

923

315/60 R22.5

145

315/45 R22.5

952
905

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59

Chassis

Wheelbase
The following table shows the possible wheelbases for the individual model designations:

Wheelbase

C1C

C1Q

C1W

C1Y

C2C

C2L

C2P

C2U

C3B

C3H

C3K

C3P

C3T

C3V

2650

3550

3700

3850

4000

4300

4600

4900

5200

5500

5800

6100

6400

6700

Code

18 t 4x2 L

963.003

S*

X*

X*

18 t 4x2 L nR

963.004

X*

25 t 6x2 L ENA

963.020

X*

25 t 6x2 L ENA nR

963.021

S*

X*

X*

X*

18 t 4x2 LS

963.403

X*

X*

18 t 4x2 LS nR

963.404

18 t 4x2 LS nRL

963.406

963.423

Model
designation
[mm]

Platform 18 t

Platform 25 t

Semitrailer tractor 18 t

Semitrailer tractor 25 t
25 t 6x2/2 LS VLA 22.5
* = New wheelbases

60

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Front axle
The suspension of the front axle is characterized by
significant weight savings compared to the predecessor model.
At the same time, optimized spring bearings provide major improvements in ride comfort and vehicle dynamics:
Grooved dampers for better ride comfort during
straightahead travel
Spring eye bearings which are soft in the
transverse direction and hard in the longitudinal
direction
Replacement of spring clamps with a clamping
brace with conventional screws (M24),
eliminating force losses due to settling and
providing better vehicle dynamics

Chassis

Suspension

Another new feature is a 1-leaf front spring with a


load capacity of 7.5 t (Q1Q) as a special version for
road vehicles with max. 32 t permissible gross vehicle weight. The weight advantage compared to the
2-leaf standard spring is approximately 21 kg. A
clever safety concept ensures that the vehicle
remains controllable even if the front spring breaks
because the spring is pressed onto the stop buffers
by the rear bearing bracket. Due to the very stiff
design of the springs, the spring travel is reduced by
roughly 20 mm.
All steel springs are asymmetric (850
mm/950 mm) and have a width of 90 mm.

The suspension features a new 2-leaf spring with a


load capacity of 8 t, providing a weight saving of
approx. 30 kg.

Overview of front springs (leaf springs)


Quantity

Code

Max. spring
load
in [t] axle load

Spring travel
[mm] from
rated load

Package
height
[mm]

Weight
[kg]

Leaf
heights
[mm]

1-leaf

Q1Q

7.5

61

46

43.57

Leaf 1: 39

2-leaf

Q1S

7.5

80

63

59.2

Leaf 1: 27
Leaf 2: 29

2-leaf

Q1T

80

63

59

Leaf 1: 27
Leaf 2: 29

3-leaf

Q1P

80

83

75

Leaf 1: 25
Leaf 2: 26
Leaf 3: 26

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61

Chassis

Suspension
Air suspension
The suspension of the air-sprung front axle (A1A)
has been almost completely redesigned. Due to the
new air suspension bellows with minimal overall
height at maximum spring travel, the bellows can be
located under the frame. This measure also
improves the ride comfort.
Furthermore, due to the elimination of the carrying
parts for the bellows, roughly 120 kg of weight
could be saved compared to the air-sprung front
axle of the predecessor model.

In order to accommodate the different frame


heights, the air-sprung variant of the front axle
comes with a total of 4 air suspension bellows variants:
830 mm for semitrailer tractors
with low frame/Lowliner
845 mm for platform vehicles with low frame
version
955 mm for semitrailer tractors
980 mm for platform vehicles with standard
frame

Front axle stabilizer bars


Two different stabilizer bars are used for road vehicles.
The standard stabilizer bar made of spring steel has
a diameter of 36 mm and a weight of roughly 15 kg.
The second variant is the stabilizer link for the airsprung front axle with a diameter of 70 mm and a
weight of roughly 34 kg.

W32.35-1044-00

Front axle with steel suspension


1 Stabilizer bar

W32.35-1045-00

Front axle with air suspension


1 Stabilizer bar

62

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Chassis

Suspension

W32.20-1033-00

Front axle with steel suspension

W32.22-1045-00

Front axle with air suspension

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63

Chassis

Suspension
Rear axle
All vehicles are equipped with 4-bellows air suspension on the rear axle and a standard stabilizer link.
On vehicles with integral rear end (C7T), the suspension has an asymmetric design due to the space
requirement of batteries and compressed air reservoirs (smaller bellows at rear). A longer lever arm on
the rear bellows supports ensures that the forces
are distributed uniformly.

An innovative attachment system - the bellows are


merely inserted into their mounts at the bottom and
fastened with a quick-release coupling at the top reduces assembly time both in the plant and for service. Decoupling of the air suspension bellows from
the lower support prevents damage to the bellows
e.g. if the vehicle is raised with a crane.

The suspension has been adjusted to the wider


frame track width. The stabilizer bearing bracket
and air bellows support components (on vehicles
without integral rear end) have been combined.

W32.22-1046-00

Rear axle with air suspension

64

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Level control (air-sprung vehicles)

Chassis

Suspension

The level control system allows the driver to freely


raise and lower the frame of air-sprung vehicles e.g.
on loading ramps, when driving under bridges,
through tunnels, when coupling and uncoupling
swap bodies and containers, when driving onto rollon/roll-off ferries etc.
The level control (CLCS) control unit is mounted on
the frame near the level control valve of the rear
axle.
It features the IP67 protection class (= dustproof
and protected against temporary immersion) and is
available in three variants:
4x2 partial air suspension with just one plug
connection
4x2 full air suspension or 6x2 partial air suspension
4x2 full air suspension and 6x2 full air suspension with roll control assistant
The desired height is changed/programmed via the
operating unit, known as the Chassis Level Control
Panel (CLCP), which is attached via a flexible helix
cable.
The CLCP has two memory buttons which can be
used to store any frame heights desired. The
heights are stored by pressing and holding the button and the CLCP indicates that storage was successful through flashing of all LEDs.

W32.33-2077-00

Level control operating unit


(CLCP=Chassis Level Control Panel)

Pressing a button activates the operating unit. A


stylized truck above the control buttons has background illumination to indicate which axle can currently be adjusted. The axle can be switched using
the "left" and "right" arrow buttons (if more than
one axle is equipped with air suspension). The
frame height can be adjusted using the "up" and
"down" arrow buttons.

The system can however also be operated via the


instrument cluster or the new multifunction key. In
addition, compulsory lowering can be stopped and
the driving level can be readjusted via a switch on
the instrument panel

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65

Chassis

Axles
Front axle
The front axles installed in the new Actros are
improved designs of the previous non-driven front
axles.
With the new model designations and new axle designations, they can be clearly distinguished from
the previous front axles.
The new non-driven front axles with permissible
axle loads of 7.5/8.0 t or 9.0 t are steered rigid
axles with forged axle housings and an offset
design. They are equipped with internally ventilated
disk brakes as standard and are installed on vehicles with both air suspension and steel suspension.
In order to accommodate the different installation
space setup of the new frame, the mounting points
of the spring packages, air bellows supports and
control arms have been modified. The stiffer design
results in less deformation and thus greater directional stability during braking. Despite the greater
rigidity, the dead weight of the axles has also been
reduced compared to comparable axles of the predecessor model.

Steering knuckle
On the steering knuckles, a "12 o'clock" position
has been introduced for mounting of the brake caliper. The raw part of the steering knuckle is thus
identical for the left-hand and the right-hand side.
The only distinction now is between steering knuckles with or without steering arm mount. The bearing
for the kingpin has been standardized for all front
axles.
Wheel head
A weight-optimized wheel flange and a wheel hub
with compact bearing are the most important features of the new wheel head for all front axles with
disk brakes.
Axle offset
The different axle offsets are used to accommodate
different frame heights and suspension concepts.

The axle track width for all non-driven front axles is


1800 mm and the distance between spring centers
remains unchanged at 840 mm.

The table below shows the front axles available at market launch:
Code

Model designation

A1C
A1D
A1E

66

Designation

Offset
[mm]

Name

739.528

F 7.5 / C 22.5

120+5

Front axle 7.5 t

approx. 427

739.505

F - 8 A / C 22.5

150+5

Front axle 8.0 t

approx. 447

739.573

F - 8 / C 22.5

120+5

Front axle 8.0 t

approx. 450

739.575

F 9 / C 22.5

120+5

Front axle 8.0 t

approx. 460

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Weight
[kg]

Chassis

Axles

W33.10-1016-00

View of front axles


A Front axle F - 7.5 / C 22.5
B Front axle F - 8 A / C 22.5

1
2
3
4

Steering knuckle (left)


Steering knuckle (right)
Steering arm mount
Kingpin bearing

W33.10-1018-00

5 Wheel head

W33.10-1017-00

C Offset

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67

Chassis

Axles
Rear axle
The new Actros makes use of the tried-and-tested
rear axles almost unchanged.
With the new model designations and new axle designations, they can be clearly distinguished from
the previous rear axles.
The axle housing of the hypoid rear axles has been
adjusted to the new frame. Due to its design, the
new wishbone control arm has to be installed on the
rear axle via two mounting points (2). This makes
the new mount (1) on the axle housing necessary.
Wishbone control arm
All 4x2 vehicles are equipped with a split wishbone
control arm instead of a one-piece wishbone control arm. This wishbone control arm consists of two
individual trailing arms (5) whose notional extension meets at the pivot point (3). This arrangement
of the pivot point (3) behind the rear axle (4)
together with the newly developed front stabilizer
bearing represents an innovation and significantly
improves handling precision, steering characteristics and lateral stability.

W35.10-1048-00

Axle housing

W35.10-1048-00

Wishbone control arm

The table below shows the rear axles available at market launch:

68

Code

Model designation

Designation

Name

A2E

746.301

R 440 - 13 A / C 22.5

Rear axle, ring gear 440, hypoid, 13.0 t

A2I

748.595

R 485 - 13 A / C 22.5

Rear axle, ring gear 485, hypoid, 13.0 t

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Leading axle (VLA)

Trailing axle (NLA)

All leading axles feature slightly modified geometry


and the wheel head of the new front axles. The rigid
leading axles of the 6x2/2 semitrailer tractors with
model designation 963.423 are manufactured by
Hendrikson, as on the predecessor model.

The unsteered trailing axles have been taken over


from current series production. The steered trailing
axles are based on the new front axles with the
same wheel head but modified steering geometry.
Trailing axles are only available with disk brakes.

Lift axles can be raised so that the tires are approx.


35 mm above the road with a fully compressed rear
axle and standard tires.

All of the trailing axles on low frame vehicles can


only be lifted but not fully raised (A4W). A steered
trailing axle is also available for platform vehicles.

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Chassis

Axles

69

Chassis

Wheel configuration
Wheel configuration
Previously, the wheel configuration identifier for
vehicles with leading and trailing axles did not indicate whether the vehicle had a leading or trailing
axle (VLA or NLA).
Accordingly, "/4" was added to the wheel configuration identifier for steered trailing axles. However,
a vehicle with steered leading axle also had the
same wheel configuration identifier (e.g. 6x2/4 LS,
mod. des. 934.223).
For future models a slash ("/") in the wheel configuration identifier will only be used for vehicles
with leading axle e.g.:

Vehicles with dual-tired trailing axle (DNA) are represented by a separate model designation:
C 96x.x25 6x2 Air DNA
This also applies to vehicles with 17.5" leading axle.
Due to the load capacity of the axles, these have a
different tonnage. However, since the tonnage is a
criterion which makes up part of the model designation, these vehicles are therefore represented by
separate model designation:
C 96x.x27

6x2/2 = 3-axle vehicle, unsteered leading axle


6x2/4 = 3-axle vehicle, steered leading axle
8x2/4 = 4-axle vehicle, steered leading axle
For steered trailing axles, there will be no specification in the wheel configuration. A 6x2 is always a
vehicle with trailing axle, which may be steered or
unsteered. Steered and rigid trailing axles will be
managed via codes. The standard version of the
corresponding model designation is always the rigid
trailing axle. This also affects 4-axle vehicles with
trailing axle in addition to the 6x2 vehicles. This
means that there is only one wheel configuration
associated with each vehicle model designation.

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Rims

Tires

Steep-shoulder rims (as per DIN 78022) of size 9.00


x 22.5 are used as standard on the new vehicles.
Aluminum rims are available as special equipment
in a shiny or matt design. All rims are 10-hole rims
except for the 17.5 inch rim for leading axles.

In general, the same tires are available for the new


product range as for the current production models.
However, due to the clearances in the front wheel
wells, the maximum possible tire size is limited to
315/80 R22.5 or 385/65 R22.5.

New rims: 11.75 x 22.5 Speedline Aluminum rims


are now also available for VLA/NLA (previously only
available for front axles), and the Speedline Aluminum rims 9.00 x 22.5 are available separately for
FA/VLA/NLA.

A spare wheel (R8P) is installed as standard, but


can also be omitted with code R9Z. The location of
the spare wheel depends on the vehicle and equipment.

Chassis

Wheels and tires

A steep-shoulder rim of size 9.75 x 22.5 is required


for 315/45 R22.5 tires. This is only available as a
steel rim to date.
A metal ring is available as a wheel nut cap for the
front axle and single-tired leading and trailing axles
under code R0Z.

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71

72

Load capacity
Single [kg]

3,400

6,150

6,700

8,000

7,500

8,000

9,000

7,300

8,000

11,600

7,100

9,000

8,000

9,500

7,100

Designation

215/75 R 17.5

315/45 R 22.5

295/55 R 22.5

295/60 R 22.5

355/50 R 22.5

315/60 R 22.5

375/50 R 22.5

385/55 R 22.5

305/70 R 22.5

315/70 R 22.5

495/45 R 22.5

295/80 R 22.5

385/65 R 22.5

315/80 R 22.5

365/70 R 22.5

12 R 22.5

Tire list

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12,600

13,400

12,600

13,400

12,600

12,600

12,300

11,600

11,600

Load capacity
Twin [kg]

67

75

72

77

66

95

62

57

66

61

57

58

50

50

50

30

Weight (approx.)
[kg]

526

526

522

517

516

491

493

485

481

457

458

437

453

438

413

372

Rdyn
(mm)

504

495

500

495

487

473

468

463

461

440

442

433

435

413

395

359

Rstat
(mm)

8.25 x 22.5

11.75 x 22.5

9.0 x 22.5

11.75 x 22.5

8.25 x 22.5

17.0 x 22.5

9.0 x 22.5

9.0 x 22.5

11.75 x 22.5

11.75 x 22.5

9.0 x 22.5

11.75 x 22.5

9.0 x 22.5

9.0 x 22.5

9.75 x 22.5

6.75 x 17.5

Rim

Only for FA

Only for FA/VLA/NLA

Only for RA

Only for FA/VLA/NLA

Only for FA/VLA/NLA

Only for FA/VLA/NLA

Only for NLA/RA

Only for RA

for 6x2/2 VLA

Remarks

Chassis

Wheels and tires

The new Actros is equipped with single-circuit


power steering of type ZF Servocom 8098.

Chassis

Steering

The steering consists of the following components:

Steering gear (ball-and-nut power steering)


Power steering pump
Power steering fluid reservoir
Hydraulic lines

W46.25-1021-00

Steering, 1-circuit (C6C)


1 Steering gear
2 Power steering pump (on engine)

3 Power steering fluid reservoir


4 Hydraulic lines

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73

Chassis

Steering
On vehicles with trailing axle 7.5 t, steered, liftable
(A4X) or with trailing axle 7.5 t, steered, liftable,
raisable (A4Y) an additional steered axle is used.
The steering consists of the following components:

Steering gear (ball-and-nut power steering)


Power steering pump
Power steering fluid reservoir
Steering cylinder for additional steered axle
Additional axle valve unit
High-pressure filter for additional steered axle
Hydraulic lines

W46.60-1075-00

Steering with additional steered axle


1
2
3
4
5
6

74

Steering gear
Power steering pump (on engine)
Power steering fluid reservoir
Hydraulic line
Steering cylinder for additional steered axle
High-pressure filter for additional steered axle

A34
B64
B65
Y39

Additional steering axle (ASA) control unit


Front axle steering angle sensor
Additional axle steering angle sensor
Additional axle valve unit

i Introduction of the New Truck Generation - The New Actros (Model 963)
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The L cab of the new Actros features an aerodynamically efficient bodyshell shape. The bodyshell of the
cabs is based on a frame structure made up of the
floor assembly, the continuous roof frame, the A
and B-pillars, the rear panel pillars, the roof bows
and the front end carrier. The panels for the individual function groups such as the roof, rear panel,
side walls and front end are welded to this frame
structure. The bodyshell concept is designed so
that the frame structure is largely of a standard
height up to the roof frame and the different cab
heights are realized by means of corresponding side
roof carriers and panels above the roof frame.

A new feature of the floor assembly are the hot


worked inner and outer longitudinal members,
which meet increased strength requirements while
conforming to the necessary tolerances. Compared
to the cab of the predecessor model, the outer
longitudinal members have a significantly stronger
design.

Design

Cab

The entire bodyshell undergoes cathodic dip


painting (KTL) as a corrosion prevention measure.

W60.00-1039-00

Bodyshell of L cab without panels

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75

Design

Cab
The following cabs will be available at market launch:

i Note
The body floor height (ASH) designates the
distance from the lower edge of the floor panel to
the uppermost row of holes in the longitudinal
frame member. On vehicles with a flat cab floor,
the body floor height is always 765 mm, on vehicles with an engine tunnel it is always 600 mm.

L cab with standard roof (ClassicSpace)


The L cab with standard roof is the entry-level version for the long-distance haulage model series and offers
high reclining and sleeping comfort. It features a wide bed with cold foam mattress and adjustable backrest
as standard.

L cab with standard roof


(ClassicSpace)

Tunnel 170 mm
(F1D)

Floor-to-ceiling height in front of seat

Flat floor
(F1M)
1590 mm

Floor-to-ceiling height on engine tunnel

1460 mm

1641 mm

L cab with Aero roof (StreamSpace)


The L cab with Aero roof has been aerodynamically optimized to reduce fuel consumption. While the high roof
version is only available with a cab width of 2.5 m, the Aero roof variant with flat floor offers the widest
possible variety with two cab widths.

L cab with Aero roof


(StreamSpace)

Flat floor
(F1F)

Flat floor
(F1I)

Width

2300 mm

2500 mm

Floor-to-ceiling height in front


of seat

1840 mm

1833 mm

Floor-to-ceiling height on
engine tunnel

76

Tunnel 170 mm
(F1E)

1785 mm

1966 mm

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L cab with high roof (BigSpace) and Giga roof (GigaSpace)

Design

Cab

The L cab with high roof or Giga roof is only available with a width of 2.5 m and a flat floor (ASH 765). It offers
more stowage space, particularly in the area above the windshield, and a greater floor-to-ceiling height in the
front area than the Aero roof version. The Giga roof provides the driver with the maximum possible space,
freedom of movement and comfort and results in an overall height of 3920 mm on long-haul vehicles e.g. with
315/80 R 22.5 tires.

L cab with high roof/Giga roof


(BigSpace/GigaSpace)

High roof
(F1H)

Width

Giga roof
(F1J)
2500 mm

Floor-to-ceiling height in front of seat

1912 mm

2054 mm

Floor-to-ceiling height on engine tunnel

1989 mm

2130 mm

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78

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2300

1590

1640
1460

0
170

Width

Floor-to-ceiling
height
in front of seat

Floor-to-ceiling
height
on engine tunnel

Height of
engine tunnel

All dimensions in mm

2300

F1D, F1M

170

1785

1840

2300

2300

F1E

1970

1840

2300

2300

F1F

L-Aero 23F

L-Standard 23

L-Aero 23

StreamSpace

ClassicSpace

Length

Code

Overview of cab range

1970

1830

2500

2300

F1I

L-Aero 25

1990

1910

2500

2300

F1H

L-High 25

BigSpace

2130

2050

2500

2300

F1J

L-Giga 25

GigaSpace

Design

Cab

Design

Cab

W00.10-1174-00

Dimensions

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79

Design

Cab
4-step entrance

ASH 765
Vehicle with air
suspension,
loaded

Standard

Low frame

Distance, step 4 - cab floor

320

320

Distance, step 3 - step 4

320

320

Distance, step 2 - step 3

320

320

Distance, step 1 - step 2

320

270

348 - 401

326 - 352

Standard

Low frame

Distance, step 3 - cab floor

370

370

Distance, step 2 - step 3

370

370

Distance, step 1 - step 2

370

370

353 - 406

281- 307

Distance, road surface - step 1

3-step entrance

ASH 600
Vehicle with air
suspension,
loaded

Distance, road surface - step 1

80

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All cab versions are suspended and mounted on


maintenance-free 4-point mounts. Reinforced cab
mounts are available for special usage conditions.
The cab mounts are available in three comfort
levels:
Standard cab mounting, steel-sprung
Comfort cab mounting, steel-sprung
Comfort cab mounting, air-sprung

A further quality improvement in cab mounting with


respect to optimized assembly has been achieved
through further development of the rear stabilizer
bearings (rubber molecular bearings). These now
feature only a single-sided end stop and their
internal design makes them self-centering. This
produces a defined gap dimension at the end stop
side during assembly.

Design

Cab mounting

The comfort mounting uses the tried-and-tested


and maintenance-free rubber friction bearings from
the current production model. They have been
further developed to be completely noise-free and,
thanks to the large volume of rubber, they offer
significantly greater comfort.

W60.80-1155-00

Comfort cab mounting, air-sprung (F3C)


1 Air bellows
2 Stabilizer bar
3 Stabilizer bar bushing

4 Rubber friction bearing


5 Transverse control arm
6 Catch

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81

Design

Cab mounting
Mounting

Cab mounting
Standard
Steel-sprung

Cab mounting
Comfort
Steel-sprung

Cab mounting
Comfort
Air-sprung

Code

F3A

F3B

F3C

Suspension type

Steel

Steel

Air

Front tuning

6.0 Hz

1.8 Hz

1.0 Hz

Rear tuning

1.8 Hz

1.8 Hz

1.0 Hz

Body floor heights


Availability

Front spring travel


in/out

765 mm, 600 mm


Standard for all L cabs
with engine tunnel

60/60 mm

35/35 mm

Intended use

Features

82

SA for all L cabs

40/40 mm

Rear spring travel


in/out

Design

Standard for all L cabs


with flat floor

Regional and national long-distance haulage

Rubber mounts with additional external dampers

Steel suspension struts

Air suspension struts with


integrated
level control

Noise-free rubber friction bearings


at cab pivot point, stabilizer bar

i Introduction of the New Truck Generation - The New Actros (Model 963)
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All cab versions are equipped with a 1-cylinder cab


tilt system. Up to a cab weight of 1400 kg, there is
a choice of a manually operated tilt mechanism and
a more convenient electrohydraulic version. As of a
cab weight of 1400 kg, only an electrohydraulic cab
tilt system can be installed.

Design

Cab tilt mechanism

When the service flap is opened in the right-hand


entrance box, the manually operated pumping
device with valve lever for adjusting the tilt direction is accessible. When tilting forwards, the cab is
automatically unlocked and when tilting backwards,
the cab is automatically locked.
Operation of electrohydraulic tilt mechanism
The cab is unlocked and the cab tilt system activated via a rocker switch on the modular switch
panel. The operating switch for the electrohydraulic
tilt mechanism is located behind the maintenance
flap on all cab versions. When the maintenance flap
is opened, the operation switch, which is attached
to a helical line, can be removed allowing the cab to
be tilted forwards and backwards from a safe
distance.
An indicator lamp on the instrument cluster indicates whether the cab is locked. The indicator lamp
must go out after the engine is started.

W60.80-1153-00

Cab tilt cylinder


1
2
3
4
5
6

Claw-type joint
Protective tube
Oil filler neck
Bearing bracket on frame
Hydraulic connection
Bearing pin

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83

Design

Seats and beds


In the new truck generation, the range of driver and
co-driver seats has been extended with new
versions for drivers who primarily travel alone.
The seat available for left-hand drive vehicles with a
2.5 m-wide cab in combination with the SoloStar
concept (D0Z) is primarily intended for drivers who
mainly travel alone, but it also allows a co-driver to
be accommodated without problem for extended
periods because the concept also offers an optional
wide, level-adjustable upper deluxe bed (D3A) and
thus 2 beds in total.
A new feature is the massage function (D2X),
which is available as special equipment for the
comfort suspension seat and air-conditioned
suspension seat for driver and co-driver.

W91.10-1377-00

SoloStar concept (D0Z)

When the function button is actuated, seven air


chambers arranged one above the other in the
backrest inflate and deflate in succession. This
creates a wave moving from bottom to top which
massages the back of the driver. The massage function is shut off automatically after 10 min. at the
latest.

W91.10-13760-00

Suspension seat with massage function (D2X)


1 Air chamber

84

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Seat variants

Material

Code for
driver seat

Code for
co-driver seat

SoloStar concept

Velour (D3Y)

D0Z

Standard suspension seat

Flat-weave fabric (D3X)


Velour (D3Y)
Imitation leather (D3Z)

D1B

Comfort suspension seat


passively ventilated

Velour (D3Y)
Leather (D3V)

D1C

D1P

Air-conditioned suspension seat


actively ventilated

Dinamica star black (D3W)


Dinamica star almond beige
(D3U)

D1D

D1Q

Function seat

Flat-weave fabric (D3X)


Velour (D3Y)
Imitation leather (D3Z)

D1N

Standard fixed seat

Flat-weave fabric (D3X)


Imitation leather (D3Z)

D1A

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Design

Seats and beds

85

Design

Seats and beds

W91.00-0000-00

Seat cover variants


A Flat-weave fabric "Skyline"
B Velour "Spyder"
C Dual-gloss imitation leather

86

D Velour "Dinamica star black"


E Velour "Dinamica star almond beige"
F Leather

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Beds
The standard equipment consists of a deluxe bed
with high-quality 7-zone cold foam mattress in
combination with a supporting spring system. The
advantages of the new deluxe bed include an
adjustable backrest instead of an adjustable headrest as well as improved access to the stowage
compartments under the bed because the bed can
be folded up completely and locked in place.

Design

Seats and beds

The variants of the beds for the L cabs result from


the different cab widths and roof heights as well as
different equipment such as air intakes positioned
diagonally opposite, stationary air conditioner etc.

Code

Standard/special

Beds

D3B

Standard for all


L cabs

Lower deluxe bed

D3C

Special equipment

Lower bed

D3F

SA for all L cabs with Aero, high


and Giga roof

Narrow upper deluxe bed, 600 mm wide

D3A

SA for all L cabs with Aero, high


and Giga roof

Wide upper deluxe bed, 750 mm, level-adjustable, manual


inclination adjustment of bed surface up to 10; automatic
extension and retraction of tensioning straps, possible in
combination with SoloStar concept (D0Z)

D3H

SA for GigaSpace in combination with SoloStar concept


(D0Z)

Upper bed, bunk approx. 600 mm wide with 50 mm mattress


thickness, folds up 90

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Design

Seats and beds

W91.75-1003-00

Upper deluxe bed

Smoke alarm
On vehicles equipped with a bed or deluxe bed, a
smoke alarm is installed above the driver door as
standard.

1 Smoke alarm

88

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W54.32-1026-00

Overview of stowage compartment volumes and available equipment

Total volume (standard)

F1D

F1M

F1E

F1F

F1I

F1H

F1J

465 l

631 l

580 l

745 l

804 l

890 l

975 l

Stowage compartments in and on dash


support

13 l

Stowage compartments above doors and in


side wall

22 l

Stowage compartments above windshield

28 l

Design

Storage and stowage compartments

21 l
28 l
137 l

29 l
161 l

247 l

332 l

Stowage space below bed, total

402 l

568 l

402 l

568 l

594 l

594 l

Stowage compartments below bed


Drawers below bed (D7J)

325 l
51 l
(SA)

420 l
112 l
(SA)

325 l
51 l
(SA)

325 l
112 l
(SA)

420 l
138 l
(SA)

420 l
138 l

F1D = L cab, 2.30 m, ClassicSpace, engine tunnel


F1M = L cab, 2.30 m, ClassicSpace, flat floor
F1E = L cab, 2.30 m, StreamSpace, engine tunnel
F1F = L cab, 2.30 m, StreamSpace, flat floor
F1I = L cab, 2.50 m, StreamSpace, flat floor
F1H = L cab, 2.50 m, BigSpace, flat floor
F1J = L cab, 2.50 m, GigaSpace, flat floor

Stowage compartments above windshield

W68.00-1016-00

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89

Design

Instrument panel
The instrument panel of the new truck generation is
designed according to the motto "same identity but
different character". It has been improved not just
in terms of appearance and ergonomics, but also in
terms of freedom of movement within the cab.
There are approx. 400 variants of the instrument
panel and they are all based on a standardized,
asymmetrically designed standard instrument
panel.
The instrument panels differ clearly in terms of their
color scheme and surface quality. The center
module of the instrument panel is aligned to be
within focus of the driver. The numerous versions of
the center module differ in terms of their size, color
and the applications installed.

New equipment components of instrument


panel

Ashtray which can be inserted in all cupholders


Bottle holder directly next to driver
Steps to upper bunk above the center module
Increase in the number of stowage
compartments in the instrument panel,
depending on the version of the center module
and by replacing dummy covers in unused installation openings in the modular switch panel with
stowage compartments
Redesigned upper stowage compartment of
instrument panel
Higher-quality appearance of instrument panel
e.g. due to softer surfaces on certain trim parts,
chrome designs on controls
Extendable folding table instead of glove
compartment on co-driver side

W68.10-1076-00

Instrument panel

90

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In addition to the redesigned instrument panel, a


new control and display concept has also been
implemented which offers greater functionality
than the previous version. This provides, for
example, improved operating comfort, greater
driving safety and, last but not least, an improved
overall visual appearance of the controls.

The following electronic components have been


improved or redesigned for this purpose:

Design

Control and display concept

Four versions of the instrument cluster in total


Electronic ignition lock (EIS) with start/stop
button
Multifunction steering wheel with left and right
button group
Right multifunction control lever for controlling
the transmission and permanent brake
Increased number of sockets for connecting
electrical consumers

W54.32-1025-00

Instrument cluster

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91

Design

Instrument cluster
General

New features

The centerpiece of the newly developed instrument


cluster is a generously sized TFT display. The instrument cluster is available in four basic versions. The
20 sub-variants are a result of the different engine
variants, because the display range of the tachometer is based on this. Furthermore, different variants are required if the tachograph is omitted and if
the reading shows mph instead of km/h. The
different language variants are implemented by the
software.

10.4 cm (4.1") or 12.7 cm (5") full color-capable


TFT display with QVGA resolution
"FleetBoard EcoSupport" driver assistance
system independent of the FleetBoard
telematics system
Intuitive control and display concept
Display of tire inflation pressure, level control
3 trip computers, shift display for 2 drivers
Display of battery status, charge balance,
starting capability
Display of gear recommendation and current
fuel consumption
Updated phone book + calling lists, SMS display
Connection capability for up to 3 cameras to the
instrument cluster with video function. A
preinstallation for a reversing camera (J9J) is
available ex factory and a suitable camera is
available as a genuine Mercedes-Benz
accessory.
Odometer display in both dial-type gauges for
displaying time and outside temperature (left
display) as well as total distance and trip
distance (right-hand display)
Operation of level control via steering wheel
buttons on air-sprung vehicles
4 virtual indicator lamp positions in the lower left
area of the TFT display which can be assigned
variably depending on the vehicle equipment or
current warning message
Extended driver data menu
Calibration of axle load characteristic via menu
Indicators for Euro VI

All variants include pointer instruments for speed,


rpm and tank content of the diesel and AdBlue
tanks. 5 indicator lamp positions are available for
body manufacturers which can be fitted with the
corresponding symbol disks.
On the instrument cluster (J1A), an internal speaker
generates noises such as the turn signal noise and
warning tones. The more advanced versions
actuate the center speaker in the stowage compartment above the windshield.
The instrument cluster is connected to the chassis
CAN via an 18-pin connector. The connector also
contains a connection to the center speaker for
outputting warning tones.
On vehicles without tachograph, an additional
connector is required for the vehicle speed information. There is also a redundant LIN connection
(Local Interconnect Network) to the EAPU (Electronic Air-Processing Unit) so that if the CAN bus
fails the brake pressures can still be displayed, as
required by law.

92

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Sound output via internal


speaker

4 layers

Sound

PCB1)

PCB = Printed circuit board

No

Video

1)

No

4.1"-TFT

Main display

Odometer display

Yellow

Instrument cluster, 10.4 cm

J1A

Lights

Designation

Code

4 layers

Sound output via center


speaker

No

Yes

4.1"-TFT

White

Instrument cluster, 10.4 cm


with additional indicators

J1B

J1E

4 layers

Sound output via center


speaker

No

Yes

5.0"-TFT

White

Instrument cluster, 12.7 cm


with additional indicators

Overview of instrument cluster variants

6 layers

Sound output via center


speaker

Yes (3 video inputs)

Yes

5.0"-TFT

White

Instrument cluster, 12.7 cm


with video function

J1C

Introduction of the New Truck Generation - The New Actros (Model 963) i

Design

Instrument cluster

93

Design

Multifunction steering wheel


The padded 4-spoke multifunction steering wheel
with 450 mm diameter is available in a leather
version (D0A) or a wood/leather version (D0D).
Compared to the predecessor model, it now offers
significantly greater control options which aid the
driver continuously.
The horn or air horn (F6Q) is actuated by pressing
the central cover.
An airbag on the driver side (S3A) is available as an
option for all vehicles.
The steering wheel height and inclination is
adjusted via a foot switch. This allows safe and
comfortable adjustment while keeping both hands
on the steering wheel. When the foot switch is
released, the steering column is locked in place
again. The height adjustment range has been
extended to 110 mm, while the inclination can be
steplessly adjusted from 28 to 47.

W46.10-1013-00

Multifunction steering wheel, leather version (D0A)

The particularly steep park position (8.5 compared


to 10.5 on the predecessor model) provides additional space during breaks and facilitates entering
and exiting the vehicle.

94

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The new truck generation is equipped with the drive


authorization system, version 3 (FBS 3).
The following control units and components
combine to form the drive authorization system:
Electronic ignition lock (EIS)
Engine management control unit (MCM)
Transmission control unit (TCM)
The electronic ignition lock (EIS) is the central
controller unit of FBS 3 in combination with the
transmitter key.

Design

Electronic ignition lock (EIS)


i Note
If one of the control units of the drive authorization
system or the electronic ignition lock (EIS) is
replaced, this must be taught into the drive authorization system with Star Diagnosis.

Removal of transmitter key (S953) with engine


running
After the engine is started, the transmitter key is
mechanically locked in the electronic ignition lock
(EIS). In this state, it is not possible to lock the
vehicle via the buttons of the transmitter key
because they are inaccessible.
However, a special mode allows the transmitter key
to be removed with the engine running. To do so,
the start/stop button must be pressed and held in
stage 1 with the engine running. The transmitter
key can then be removed. The message "Only
maneuvering speed possible" then appears on the
multifunction display of the instrument cluster.

W80.57-1017-00

S1
S953

Electronic ignition lock (EIS)


Transmitter key

Start/stop button

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95

Design

Transmitter key
The transmitter key (S953) is available in the
following three variants:
Low (F8A)
2 vehicle keys - no radio signal transmitter
Standard (F8B)
2 remote control keys - with unidirectional radio
signal receiver
Multi-function (F8C)
1 multifunction and 1 remote-control key - with bidirectional radio signal receiver/transmitter

Transmitter key (S953), Low variant


Integrated slide-out mechanical key (2)

W80.57-1014-00

Transmitter key (S953), Standard variant

Integrated slide-out mechanical key


Unidirectional radio signal transmitter, 433 MHz
Coin cell
Battery capacity detection (visualized via
instrument cluster)
Locking and unlocking button for central locking
(range approx. 30 m)
The radio signals transmitted by the transmitter key
(S953) are received by the electronic ignition lock
(EIS) via a 30 cm antenna line integrated in the cab
wiring harness.
W80.57-1015-00

96

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Transmitter key (S953), multi-function variant

Design

Transmitter key

Bidirectional radio signal transmitter, 433 MHz


Li-ion rechargeable battery (inductively charged
via the electronic ignition lock (EIS))
Locking/unlocking button for central locking
(range approx. 30 m)
Removable mechanical key
4.5 cm (1.8") TFT color display
4-way control with central input button
Display and operation of various vehicle
functions (range approx. 100 m)
The radio signals transmitted and received by the
transmitter key (S953) are received/transmitted by
an antenna on the cab roof.

W80.57-1016-00

1
2
3
4
5
6
7

Main menu tabs


Display area for menu windows
Navigation button
Input button
Battery charge level indicator
Key radio signal strength
Submenu tabs

S953 Transmitter key

Depending on the equipment of the vehicle, the


following equipment can be controlled using the
multi-function transmitter key:

Depending on the equipment of the vehicle, the


following information can be displayed on the multifunction transmitter key:

Level control
Auxiliary heater on/off
Stationary air conditioner on/off
Interior lights
Locking and unlocking of doors, side windows
and tilting roof
Work lamps
Unlocking of cargo liftgate
Radio

Total mileage/operating hours


Lights status
Status of tire pressure monitor
Events recorded in instrument cluster
Fill levels of fuel and AdBlue
Exterior and interior temperature
Axle load
Reservoir pressure of compressed air system
Status of doors and flaps in combination with
alarm system

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97

W00.19-1056-00

Overall network

Networking

Overall network

98

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Networking

W00.19-1057-00

Overall network

99

100

A10c

A10b

A9
A10

A8

A7

A6

A5

A4

A3

A2 a3

A2 a1
A2 a2

A2

A1

Instrument cluster (ICUC)


control unit
Central gateway (CGW)
control unit
Central data memory (CDS)
Communications interface
(COM) control unit
Maintenance system (MS)
control unit
Drive control (CPC) control
unit
Engine management control
unit (MCM)
Transmission control unit
(TCM)
Anti-theft alarm system (ATA)
control unit
Cab sensor and actuator
module (SCA)
Frame sensor and actuator
module (SCH)
Truck Control Center (TCC)
Antilock brake system (ABS)
control unit, 4-channel
Electronic brake control (EBS)
control unit
Electronic brake control (EBS)
control unit

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A28
A30

A26

A25a

A25

A22

A21a

A21

A20a

A20

A18

A17

A16

A15

A14

A13

A12b

A11

Retarder control unit


(RCM)
Heating, ventilation and air
conditioning (HVAC) control
unit
TRUCK auxiliary heater (ITH)
control unit
Stationary air conditioning
(IAC) control unit
Front radar sensor
(RDF) control unit
Driver door module (DCMD)
control unit
Front passenger door module
(DCMP) control unit
Electronic Air-Processing Unit
(EAPU) control unit
Front axle axle modulator
(Wabco)
Front axle axle modulator
(Knorr)
Rear axle axle modulator
(Wabco)
Rear axle axle modulator
(Knorr)
Parameterizable special
module (PSM) control unit
Electronic Stability Program
(ESP) control unit
(Wabco)
Electronic Stability Program
(ESP) control unit
(Knorr)
Level control (CLCS) control
unit
Driver switch group
FleetBoard control unit
B81
G1a

A72
B42
B43
B66

A70

A58
A60

A57

A55

A54

A53

A43

A40

A35

A34

A33

Battery disconnect switch


control unit (BESO)
Additional steering axle (ASA)
control unit
Tire pressure monitor (TPM)
control unit
Supplemental restraint
system (SRS) control unit
Modular switch panel (MSF)
control unit
Driver assistance system
(VRDU) control unit
Lower radiator shutters
controller unit
Upper radiator shutters
controller unit
NOx sensor control unit
upstream of diesel oxidation
catalytic converter
SCR control unit
Exhaust aftertreatment (ACM)
control unit
NOx sensor control unit
downstream of SCR catalytic
converter
Lane Assistant camera
Alarm siren
Interior protection sensor
Steering wheel angle sensor
(SAS)
Rain and light sensor (RLS)
Battery sensor (IBS)

Electronic ignition lock (EIS)


Left multifunction control
lever
S22 Level control operating unit
S23 Right multifunction control
lever
S110
Left multifunction
steering wheel button
group
S111
Right multifunction
steering wheel button
group
X100.16 Diagnostic socket
X102.15 Trailer socket,
15-pin
X12.7
ABS trailer socket,
7-pin
X167.12 Electrical
connector
X910
Electrical
connector
XR-E1H Cable weld point
Exterior 1 CAN-H
XR-E1L Cable weld point
Exterior 1 CAN-L
XR-E1M Cable weld point
Exterior 1 CAN ground

S1
S20

Networking

Overall network

ASIC data bus


(Application System
Integrated Circuit)
Exterior CAN
Interior CAN
Frame CAN
Drive train CAN
Climate control CAN
Front axles brakes
CAN
Rear axle brakes CAN
Redundant brakes CAN
ESP brakes CAN
Trailer CAN (PSM)
Body CAN (PSM)
Telematics CAN
Diagnostic CAN
Trailer CAN (EBS)
Radar CAN
NOx CAN

CAN bus star point


cab instrument panel
CAN bus star point
frame
CAN bus star point
powerplant
LIN 5
LIN 6
LIN 7
LIN 8
LIN 9
LIN 10
LIN 11

LIN 4

LIN 1
LIN 2
LIN 3

Rain/light sensor LIN


Battery sensor LIN
Right multifunction control
lever LIN
Left multifunction control
lever LIN
Radiator shutters LIN
SCA/SCH redundancy LIN
Button group LIN
Level control LIN
Driver switch panel LIN
EAPU-LIN
ATA-LIN

Introduction of the New Truck Generation - The New Actros (Model 963) i

101

CAN 6b
CAN 6c
CAN 6d
CAN 7
CAN 8
CAN 9
CAN 10
CAN 11
CAN 12
CAN 13

Networking

CAN 1
CAN 2
CAN 3
CAN 4
CAN 5
CAN 6a

ASIC

Z4

Z3

Z1

Overall network

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Networking
102

Overall network
General

CAN data bus system

Due to the increase in electronic systems in the


new truck generation, more and more signals have
to be made available throughout the system. This
mainly affects the network, which has further
increased in complexity. Alongside the familiar CAN
and ASIC data bus systems, the LIN data bus is now
being used increasingly. In the new Actros, there
are 11 LIN data buses alone to connect the various
control units, switches and other electronic components to each other. On the other hand, the number
of CAN data buses has only increased slightly.

The CAN data bus system makes it possible to


exchange information between control units quickly
and reliably using few lines. In this case, the information is transmitted and received in succession
(serial). Exchange takes place on a bidirectional
basis i.e. every control unit acts as both a transmitter and a receiver.
On the new Actros, there is no longer a direct
connection from the telematics CAN (CAN 9) to the
diagnostic socket.

CAN bus

Transfer rate
[kBaud]

Exterior CAN (CAN 1)

500

Interior CAN (CAN 2)

500

Frame CAN (CAN 3)

500

Drive train CAN (CAN 4)

667

Climate control CAN (CAN 5)

500

Front axle brakes CAN (CAN 6a)

500

Rear axle brakes CAN (CAN 6b)

500

Redundant brakes CAN (CAN 6c)

500

ESP brakes CAN (CAN 6d)

500

Trailer CAN (PSM) (CAN 7)

125

Body CAN (PSM) (CAN 8)

125

Telematics CAN (CAN 9)

250

Diagnostic CAN (CAN 10)

500

Trailer CAN (EBS) (CAN 11)

125

Radar CAN (CAN 12)

500

NOx CAN (CAN 13)

250

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Battery sensor (IBS)


The battery sensor (IBS) (G1a) is integrated in the
terminal clamp of the negative terminal in the
battery cable. The battery sensor (IBS) determines
the charge level and starting capability of the
batteries and transmits this information upon
request via the battery sensor LIN to the cab sensor
and actuator module (SCA).

Networking

Overall network

Prerequisites
The electronic ignition lock (EIS) is switched to
"Terminal 15 ON".
The battery capacity is correctly parameterized
in the instrument cluster control unit (ICUC) and
in the cab sensor and actuator module (SCA).
The battery sensor (IBS) has not been newly
connected.

W54.10-1134-00

G1
G1a

Battery
Battery sensor (IBS)

The battery status can be viewed at any time under


the "Monitoring info" menu item in the multifunction display of the instrument cluster.
In addition, the driver is actively informed by appropriate messages on the multifunction display if the
battery charge level drops below a certain value.

i Note
A correct charge level value for the batteries is
only displayed on the multifunction display of the
instrument cluster after roughly 20 starting procedures.

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103

Networking

On-board electrical system


Power supply
The standard power supply consists of two maintenance-free 12 V batteries each with a capacity of
170 Ah and a weight of approx. 94 kg. Larger
batteries (2x12 V 220 Ah) are available under code
(E1C) and may also be required depending on the
equipment. The higher capacity variant has a
combined weight of roughly 120 kg.
The battery and energy management system
equipped as standard continuously monitors the
status of the battery and actively shuts off comfort
consumers before the battery charge level drops
below the value required to start the engine.

The sensor is connected to the cab sensor and actuator module (SCA) via the battery sensor LIN. The
module evaluates the signals and determines the
minimum battery charge level required for starting.
Before the minimum battery charge level is dropped
below, the cab sensor and actuator module (SCA)
shuts off the heater blower and radio via the cab
CAN. If this measure is not sufficiently effective (the
battery charge level drops even further), two warnings are issued on the multifunction display. The
first warning stage prompts the driver to shut off
further consumers. A brief warning tone sounds and
a visual warning is issued on the multifunction
display. For the second warning stage, 3 brief
warning tones sound and the driver is prompted to
start the engine.
The limits of the consumer shutoff function can be
parameterized. The charge level of the battery can
be displayed on the monitoring info menu of the
multifunction display.

Alternator
Alternators produced either by Delco Remy (100 A
variant only) or Bosch are used. A total of three
versions are available:

Manufacturer

104

Model

Delco Remy

28SI

Bosch

HD10

Bosch

HD10P

Code

E1N
E1M

Rated voltage (V)

Rated current (A) at alternator rpm


1800 rpm

6000 rpm

28

41

100

28

42

100

28

30

150

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Sockets
Compared to the predecessor model, there are
extra connection options for additional consumers.
In the new Actros, up to 5 power outlets are available in the cab.
Cigarette lighter 24 V/4 A, dash support, standard (Y1Z)
Socket 24 V/15 A, max. 600 W, dash support,
standard (E3F/E3I)
Socket 24 V/15 A, front passenger footwell,
standard (E3L)
Additional socket 12 V/15 A, front passenger
footwell, SA (E3E)
Additional socket 24 V/15 A, front passenger
footwell, SA (E3Q)
Power socket 24 V/25 A, max. 600 W, front
passenger footwell, SA (E3R)
Socket 24 V/15 A, in right side wall stowage
compartment, SA (E3S)
Socket 24 V/15 A, behind seat, SA (E3M)

Networking

On-board electrical system

W54.10-1142-00

Power socket 24 V/25 A (E3R)


1 PowerPort
2 PowerClip

The Power socket is available as special equipment


instead of the standard socket (E3L). This socket is
equipped with the MagCodePowerSystem for safe
connections. Here, the contact is closed by magnets
but other metallic objects cannot initiate switching.
This makes the system extremely short circuit-resistant. The corresponding mating connectors are also
supplied so that the customer can fit them to their
own devices.

W54.10-1143-00

Coffee machine with Power socket

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105

Lights

Exterior lights
Headlamps

W82.10-1107-00

Halogen headlamps (standard)

The following lighting equipment comes as standard in the new Actros:


Standing lights, low beams and high beams with
additional "Ambient illumination" function
Turn signals and hazard warning system with
additional "One-touch turn signaling" function
Front fog lamps
Rear foglamp, backup lamps and brake lights
LED clearance lamps
LED side marker lamps

106

W82.10-1108-00

Bi-xenon headlamps (L1A)

Available as special equipment:

Code (L1A) Bi-xenon headlamps


Code (L1B) Daytime running lights
Code (L1H) Front fog lamps, halogen
Code (L1I) Front fog lamps, LED daytime running
lights
Code (L1N) Front fog lamps, LED daytime
running lights, cornering lights
Code (L3A) Lower work lamps
Code (L3C) Work lamps at top of cab rear panel
Code (F0T) Illuminated Mercedes star

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Halogen headlamps

Bi-xenon headlamps (L1A)

The new Actros is equipped with halogen headlamps as standard.

A bi-xenon variant is available for all vehicles with


rear axle air suspension as special equipment.

The halogen headlamps feature 4-reflector technology and incorporate the functions of the high
beams, low beams, daytime running lights and turn
signal lamps, each with their own free-form reflectors; the standing lights are integrated in the low
beams. On vehicles equipped with the LED daytime
running lights special equipment option, the
daytime running lights integrated in the halogen
headlamps are omitted.

A headlamp cleaning system (L3Z) is always


required in combination with the bi-xenon headlamps.

The daytime running lights (L1B) can be integrated


in the halogen headlamps upon request or as standard in countries with corresponding legislation (as
of August 2012 daytime running lights are compulsory on all new commercial vehicle models as per
ECE-R 48). The additional H21 W bulb comes on as
soon as the engine is started, but not if the low
beams are switched on. In order to help increase
the service life of this light source, the cab sensor
and actuator module (SCA) reduces the supply
voltage by means of pulse width modulation (PWM)
to 23.8 V.
The same electronics filter out any voltage peaks
which occur and increase the service life of the light
sources (H7 for low beams, H1 for high beams,
PY21 W for turn signals).

Lights

Exterior lights

Front fog lamps, halogen (L1H, standard


with Giga roof cab (F1J))
The front fog lamps are located underneath the
main headlamps. The covering lens is made of hardened pressed glass and is bonded to the housing.
The light source used (H11) ensures an optimally
aligned glow coil at the focal point of the reflector.

Front fog lamps, LED daytime running


lights, cornering lights (L1N)
A specially designed reflector ensures that both the
fog lamp requirements (both lamps switched on)
and the low beam requirements (left or right-hand
lamp switched on) can be met. The low beams are
controlled via the cab sensor and actuator module
(SCA).

Instead of the pressed glass lens used previously, a


plastic lens is used on the halogen headlamps. This
is coated with a paint system which, on the one
hand, has a high resistance to UV radiation and, on
the other hand, is scratch-resistant. The advantages of the plastic lens are its resistance to stone
chipping and its lower mass compared to glass.

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107

Lights

Exterior lights
Front fog lamps, LED daytime running lights
(L1I)
The daytime running lights consist of 5 LEDs. The
drive electronics, which incorporate a constantcurrent supply, reverse polarity protection, overvoltage protection and an EMC circuit, are integrated in each lamp. The constant-current supply
ensures uniform light output in the event of voltage
fluctuations. An aluminium heat sink leading
outside the vehicle is used to cool the LEDs. This
special cooling system is necessary to control the
temperature balance and thus achieve the required
service life of approx. 30,000 h. If LED daytime
running lights are installed, the daytime running
light function in the halogen headlamps is omitted.

108

W82.10-1109-00

Front fog lamps, LED daytime running lights

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Lights

Exterior lights
Function
The lighting equipment for the exterior lights is
actuated and monitored by the cab sensor and
actuator module (SCA) and the frame sensor and
actuator module (SCH).
Cab sensor and actuator module (SCA)
The cab sensor and actuator module (SCA) contains
the switching logic for the lighting equipment at the
front end of the vehicle as well as controlling and
monitoring the trailer lighting and generating the
flashing frequency of the turn signal system.
The following lighting equipment is connected to
the cab sensor and actuator module (SCA):

Left turn signal lamp and side marker lamp


Right turn signal lamp and side marker lamp
Left headlamp
Right headlamp
Left front clearance lamp
Right front clearance lamp
Left front fog lamp and daytime running lamp
Right front fog lamp and daytime running lamp

On vehicles with illuminated Mercedes star (F0T),


the illumination of the Mercedes star is also actuated and monitored and on vehicles with lower
work lamps (L3A) or work lamps at the top of the
cab rear panel (L3C) the swiveling work lamps are
actuated and monitored.

Frame sensor and actuator module (SCH)


The frame sensor and actuator module (SCH) actuates and monitors the lighting equipment at the
rear of the vehicle. This includes:

Left rear lamp unit


Right rear lamp unit
Left side marker lamp 1
Right side marker lamp 1

Emergency operation concept


Supply with terminal 30
The frame sensor and actuator module (SCH) is
equipped with 2 power supply lines. If one of these
lines fails, some of the lighting equipment will
remain functional.
Supply with terminal 31
There is no redundant supply with terminal 31. The
terminal 31 supply line is however monitored and
open circuits are detected.
CAN redundancy
The SCA/SCH redundancy LIN provides CAN
redundancy between the cab sensor and actuator
module (SCA) and the frame sensor and actuator
module (SCH).

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109

Lights

Exterior lights
Rear lamps
The 6-chamber rear lamps have been redesigned.
They are also available in an LED version as special
equipment (L1P).
Instead of the usual bulbs, the rear lamps are then
equipped with energy-saving and long-life LEDs for
the turn signal, brake light, position lamp and taillight functions. In addition to their long service life,
the use of LEDs also provides a further safety
advantage due to the quicker response of the brake
lights.
The rear fog lamp and backup lamp functions are
each performed by a 21 W bulb and the license
plate lamp takes the form of a 10 W bulb.
Backup warning system
An acoustic backup warning system integrated in
the rear lamps is available for all rear lamps and in
two variants.
The standard version (E6Z) can be switched off via
a switch on the instrument panel. The backup
warning system is combined with the hazard
warning system (E6Y) especially for the law in
Austria. When this version is switched off, only the
hazard warning system flashes when reverse gear is
engaged.
On both versions, the sound level can be reduced
from approx. 73 dB (A) to approx. 55 dB (A) by
engaging reverse gear twice within 7 seconds.

Clearance lamp
The LED clearance lamp installed as standard
contains 4 LEDs. Due to the use of a current control
system, the light output remains constant in the
event of voltage fluctuations. The light geometry
has been designed to allow installation on 4
different roof variants and 2 sun visor variants.

110

1 Right taillamp
2 Backup warning system

W82.10-1110-00

Side marker lamp


LED side marker lamps form part of the standard
equipment. Their number varies depending on the
length of the vehicle.

Ambient illumination
("Follow-Me-Home" illumination)
Ambient illumination forms part of the basic scope
of all vehicles. After the doors are opened or shut,
the headlamps and the interior lights remain on for
a certain period of time. The desired period of time
can be set on the instrument cluster in 15 s steps.
The function is activated by unlocking the vehicle
(e.g. using the radio remote control) or by opening
the doors. In combination with the rain and light
sensor (F8X) (RLS), the light only switches on if the
RLS detects darkness.
The lighting equipment which can be selected for
this function in the instrument cluster includes:

Marker lamps
Fog lamps
Low beams
Daytime running lights

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The interior illumination incorporates:

Scope of ambiance illumination (D5B):

"Night sky" lights (6 LEDs)


Stowage compartment above windshield (4
LEDs)
Footwell trim/passenger footwell (2 LEDs)
Steering column trim (2 LEDs)

Driver/passenger reading lamp


Bunk reading lamp
Interior lights
Night illumination (green) as antiglare
orientation lighting while driving
Ambience illumination (blue) as interior illumination with the vehicle parked

Lights

Interior lights

The lighting functions are activated/deactivated by


operating the following switches:
Switch panel above the windshield
Front passenger door switch panel
Bunk switch panel
The interior lights can be switched off globally via
the interior light switch in the bunk switch panel.

Ambiance illumination (shows "night sky" lights and lights of stowage compartment above windshield) W82.20-1044-00

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111

Safety

Active Brake Assist 2


Active Brake Assist 2 (ABA) (S1C) monitors the
traffic situation ahead of the vehicle by using data
from the vehicle and by determining distances to
the vehicle ahead and its speed. The system can
only monitor vehicles in the same lane or stationary
objects which are straight ahead, but not oncoming
vehicles. If the system detects a danger of a rearend collision, the driver is informed of the danger by
a three-stage warning system.
1st warning phase
Visual (red) warning on instrument cluster and
acoustic warning in the form of an intermittent
warning tone, radio is muted.
2nd warning phase
A gentle brake intervention is carried out in addition
to the visual and acoustic warning (deceleration of
approx. 3 m/s2)

ABA can be shut off manually at any time. The


status "ABA deactivated" is shown by an indicator
lamp on the instrument cluster. The visual warning
on the instrument cluster remains active even when
the system is switched off. When emergency
braking is triggered, the hazard warning flasher is
also actuated simultaneously with an increased
flashing frequency in order to draw the attention of
the road users behind the vehicle to the danger.
After the emergency brake application, the flashing
frequency is reduced to normal.

i Note
Only the 1st and 2nd warning stages are triggered
for stationary obstacles, but emergency braking is
not triggered.

3rd warning phase


Emergency braking is automatically triggered (only
if obstacles are still traveling)
Until the emergency brake application actually
occurs, it can be aborted as follows by driver intervention:

Actuation of right multifunction control lever


Actuation of brake pedal
Actuation of accelerator pedal
Actuation of steering wheel
Actuation of Active Brake Assist button

i Note
Emergency braking is always carried out with the
maximum brake pressure and does not adjust
automatically to the weather and road conditions.
After the emergency brake application, the vehicle
is held by the brake automatically for a maximum
of 5 s.

Once emergency braking has been triggered, it can


only be aborted by pressing the Active Brake Assist
button or by depressing the accelerator pedal to the
kickdown position.

W54.25-1192-00

ABA OFF button

112

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A front radar sensor is installed in the front bumper


for the ABA and Proximity Control Assist functions.
In the new Actros, a 3rd generation sensor manufactured by Continental is used. Although the size
of the housing is smaller compared to the predecessor model, this front radar sensor has a larger
sensing range. It has the following additional advantages:

Self-calibration also takes place during driving operation (vehicle speed v > 30 km/h). If the sensor
cannot adjust itself within the required tolerances,
a fault message is shown on the multifunction
display.

The front radar sensor is self-calibrating, which


eliminates the need for complex calibration at
the plant
In future, ABA and Proximity Control Assist will
also be available on steel-sprung vehicles
Improved short-range scanning
More powerful electronics, allowing the system
to also detect stationary obstacles

Frequency range: 76 to 77 GHz

Safety

Active Brake Assist 2

Technical data:
Connection: 8-pin connector (watertight)
Short range coverage: 56, range 0.25 to 50 m
Long range coverage: 18, range 0 to 200 m

W54.32-1027-00

Warning indicator in multifunction display

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113

Safety

Stability control assistant


The Electronic Stability Program (ESP) is available
in the form of the stability control assistant (S1D).
In critical driving situations, e.g. sudden evasive
maneuvers or high cornering speeds, it prevents
the vehicle from skidding, jackknifing or rolling
over.
It operates irrespective of the load condition or road
surface condition. For vehicles with initial registration as of 11/2011, the Electronic Stability
Program (ESP) must be installed as standard in
ECE countries.
The stability control assistant is now available for all
2 and 3-axle vehicles (except all-wheel drive vehicles).

In a critical driving situation, the following automatic control interventions stabilize the vehicle:
Reduction in engine torque
Selective braking of individual wheels on tractor
vehicle
Selective actuation of semitrailer/trailer brake
system
Braking of entire tractor/trailer combination
The stability control assistant is only active during
driving operation and at a vehicle speed of
v > 10 km/h. It does not operate with reverse gear
engaged.

In the case of vehicles which do not require stability


control due to aftermarket modifications or registration in a non-ECE country, it can be omitted with
code (S9Z).
The Electronic Stability Program (ESP) control unit
contains a lateral acceleration sensor and a yaw
rate sensor. In addition, the desired driving direction of the driver is detected via a steering wheel
angle sensor. Together with signals from the wheel
speed sensors, the control unit can detect deviations of the vehicle from its intended path.

W42.45-1038-00

A25a

114

Electronic Stability Program (ESP)

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control unit

General
The Lane Keeping Assist system (S1H) is available
for all vehicles as special equipment and will also
eventually become compulsory on new vehicles. As
of November 2013, the active safety system will
become a legal requirement on all new vehicle
models (passenger cars and commercial vehicles)
which are registered in the European Union. This
will apply to all new vehicles as of November 2015.

Function
As of a speed of roughly 60 km/h, a digital camera
behind the windshield records the vehicle position
relative to the left-hand and right-hand lane markings. A powerful microcomputer continuously evaluates the images recorded. When the vehicle
crosses over a lane marking, a warning signal (highfrequency rattling) from the corresponding lefthand or right-hand door speaker sounds for roughly
1.5 to 4 seconds.

Safety

Lane Keeping Assist


Due to the following optimizations of the Lane
Keeping Assist system, it is expected that the
system will enjoy significantly greater acceptance
from drivers:
An improved camera and modified algorithm
produce significantly fewer incorrect warnings
By separating the camera and the electronics,
the housing of the camera, which also houses
the rain and light sensor, has been made significantly smaller and thus restricts the view out of
the windshield less.
The system indicator in the lower left area of the
multifunction display is displayed permanently.
The indicator differentiates between continuous
and broken lines.
The system is able to detect ambiguous lane
markings ("construction site detection") and
then switches to a passive mode. This also
applies to tight corners and narrow lanes.
The volume of the radio is reduced while the
warning tone is output, but not completely
muted as previously

At the same time, the vehicle's lane deviation is


indicated on the instrument cluster. The visual indication is also issued if acoustic warnings are
suppressed due to driver activities, but not in
passive mode.
Lane Keeping Assist is a support system only and
does not intervene actively in the driving situation.
If the driver actuates the accelerator pedal, turn
signal or brake, the warning signal is suppressed.
As on the predecessor model, Lane Keeping Assist
can be switched off via a button on the instrument
panel. The status "deactivated" is indicated by the
LED in the button.

W54.32-1022-00

Left Lane Keeping Assist warning indicator

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115

Safety

Roll control assistant


The purpose of the roll control assistant (S1F) is to
adjust the suspension damping selectively to the
respective driving situation and is only available for
air-sprung vehicles because the function is incorporated in the level control (CLCS) control unit. If the
roll control system is requested, the full version of
the level control (CLCS) control unit is always
installed.
On all air-sprung semitrailer tractors, the standard
level control system (CLCS) can be extended to the
roll control assistant. The functions of the roll
control assistant are enabled for each axle via
parameters. Up to four axles can be actuated.
The control logic records the measured sensor
signals e.g. vehicle speed, steering wheel angle,
brake pressure and spring travel and uses these to
determine the current load condition and current
driving situation. Based on this information, it
switches the shock absorbers between hard,
safety-focussed tuning and soft, comfortable
tuning.
There are always two shock absorbers installed on
each axle, each featuring an electrically actuated
proportional damping valve. These are actuated
steplessly on an axle-by-axle basis. On partially airsprung vehicles, shock absorbers with roll control
are also installed on the steel-sprung front axle.

W32.34-1025-00

Roll control damper


1
2
3
4
5

Piston rod
Seal and guide unit
Working cylinder
Compensation chamber for holding displaced fluid
Working piston and piston valve, optionally with linear
or degressive characteristics
6 Bottom valve with special bores, springs and valves for
exact adjustment of the damping force
7 External proportional valve

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A tire pressure monitor (S1Y) which has been


improved in key areas is available for all model
designations. The system supports the driver by
displaying the tire inflation pressure on the multifunction display. Correct tire inflation pressure
increases the service life of the tires and lowers fuel
consumption.
Previously, the wireless tire pressure monitor was
only available in combination with super single
tires. The new tire pressure monitor, on the other
hand, is available for almost all tire sizes and types
and for vehicles with up to 4 axles. Furthermore, it
is not necessary to manually teach-in the wheel
sensors to their positions on the vehicle. The automatic position detection is based on evaluation of
the strength of the signal reception and detection of
rotation direction.
Based on these variables, the signals from the
wheel sensors can be assigned to their position on
the vehicle. Due to detection of the rotation direction, this only takes place as of a speed of
v > 7 km/h.
There is a wheel sensor in each rim, which detects
the tire temperature and tire inflation pressure.
They are supplied with power by a lithium battery.
The integrated high-frequency transmitters
transmit a radio data telegram at a frequency of
433 MHz to the antenna, which in turn forwards it
via the system's dedicated CAN bus to the tire pressure monitor (TPM) control unit in the cab. The radio
data telegram contains the following information,
for example:

Safety

Tire pressure monitor


The wheel sensors are installed inside each individual tire and are screwed to the rim with the valve,
which identified by a colored ring.
The intended service life of the battery is roughly
5 years. The current charge level of the battery of
each individual wheel sensor is displayed in the tire
pressure monitor menu. In addition, roughly
6 months before the battery becomes empty, the
driver is prompted via the instrument cluster to also
have the wheel sensors changed during the next
tire change. Since the sensors are sealed for
strength-related reasons, the entire wheel sensor is
always replaced.
The specified pressure is set at the plant based on
the tire size, type and manufacturer for a temperature of 20 C and can also be read out on the instrument cluster. If the tire size is changed, the specified pressure must also be re-parameterized with
Star Diagnosis.
Deviations of the tire inflation pressure from the
specified pressure are detected by the tire pressure
monitor. When the set limits are reached, a warning
is issued via the multifunction display. Since the tire
inflation pressure varies according to the temperature, the tire pressure monitor always performs
automatic corrections of the warning thresholds at
elevated temperatures.

ID of wheel sensors
Current tire inflation pressure in bar
Current tire air temperature
Charge level of lithium battery

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Safety

Tire pressure monitor


The wheel sensors are screwed to the wheel
shoulder with the filling valve and are identified by
a colored ring on the filling valve.

1 Wheel sensor

W40.15-1039-00

W40.15-1028-00

Tire pressure monitor, location of components

118

Wheel sensors

A35
W3
W6
W7
W8
W9

Tire pressure monitor (TPM) control unit


Antenna of 1st front axle
Left antenna of 1st driven rear axle
Right antenna of 1st driven rear axle
Left antenna of 2nd driven rear axle/trailing axle
Right antenna of 2nd driven rear axle/trailing axle

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Safety

Tire pressure monitor


Indicators on multifunction display
1 Tire menu selection
2 Front axle tire pressure indicator
3 Rear axle tire pressure indicator

W40.15-1036-00

4
5
6
7

Axle 1 menu selection


Tire pressure indicator
Tire temperature indicator
Battery charge level

W40.15-1037-00

8
9
10
11

Axle 2 menu selection


Tire pressure indicator
Tire temperature indicator
Battery charge level

W40.15-1038-00

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Driving assistance systems

Proximity Control Assist


Autonomous intelligent cruise control (ART) is available in the form of Proximity Control Assist (S1I) for
all vehicles in combination with Mercedes PowerShift 3. For the first time, Proximity Control Assist
can also be installed on the new Actros without
retarder.
The most important new feature of Proximity
Control Assist is, however, its ability to operate
even at speeds of below 15 km/h.
Using the front radar sensor installed in the
bumper, Proximity Control Assist detects the vehicles in front and automatically maintains a set
distance from them. It brakes automatically at
maximum deceleration down to a complete standstill.
However, Proximity Control Assist can only intervene for stationary vehicles which were previously
detected as driving. Accordingly, the system cannot
intervene for stationary objects such as stationary
vehicles (end of traffic jam) or obstacles on the
road.
For safety reasons, the vehicle does not start off
again automatically after being stationary for more
than 2 seconds. Instead, this must be initiated by
the driver either by depressing the accelerator
pedal or by pressing the "RES" button on the right
button group of the multifunction steering wheel.
In terms of the control interventions of the system,
it must be noted that for safety reasons brake interventions at speeds of between 15 90 km/h are
limited to 2 m/s2, and at speeds of below 15 km/h
to max. 3 m/s2. If the traffic situation requires
greater deceleration, the driver is informed of this
by a visual/acoustic distance warning so that the
deceleration can be increased by operating the
brake pedal if necessary. Without any vehicles in
front, Proximity Control Assist is deactivated below
5 km/h.

The desired distance to the vehicle in front can be


adjusted in 5 steps (instead of 7 previously) from a
minimum of 1.5 to a maximum of 3.6 seconds. After
the ignition is switched off, the medium value is
always preset which corresponds to a time distance
of 2.2 seconds. At a speed of 80 km/h this corresponds to a distance from the vehicle in front of
roughly 49 m. With the vehicle stationary, a
minimum distance of 4 m is maintained.
Proximity Control Assist only operates when the
driver is seated in the driver seat. This is continuously checked by a seat occupied sensor. For this
reason, Proximity Control Assist is currently only
available in combination with the comfort driver
suspension seat (D1C) or air-conditioned driver
suspension seat (D1D).
Fault messages from Proximity Control Assist are
output via a yellow warning on the instrument
cluster and a warning tone which is of a lower
frequency than the messages from Active Brake
Assist 2.
If the cruise control functions are operated via the
steering wheel buttons, incorrect operation is
possible under certain circumstances e.g. several
buttons are pressed simultaneously. A plausibility
checking function in the drive control (CPC) control
unit checks which operation makes sense. The "Off"
button and the "RES" button always have priority in
this case for safety reasons.

A15

120

Front radar sensor (RDF) control unit

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W30.30-1093-00

The JSK 37 and JSK 42 fifth wheel couplings from


JOST are also available with sensing technology
both in the standard and in the compact versions.
They feature sensor-assisted monitoring of the
locking system and remote indication of the
coupling status to provide additional comfort and
safety when coupling or uncoupling a trailer and
during driving operation.
In the case of sensed fifth wheel couplings, it is still
necessary to manually open the fifth wheel coupling
when uncoupling a trailer but there is no need for
visual inspection of the fifth wheel coupling after a
trailer is successfully coupled because the coupling
status is displayed on the instrument cluster.
The fifth wheel coupling is monitored by three
sensors:

1 Locking status sensor


2 Kingpin sensor
3 Semi-trailer plate sensor

Driving assistance systems

Sensed fifth wheel coupling

W31.10-1026-00

The sensor for the locking status has a


redundant design and incorporates 2 reed
switches for reliable sensing of the locking
process.
An inductive sensor monitors the position of the
kingpin.
A third sensor (also inductive) indicates contact
with the semi-trailer plate, thus making coupling
easier.

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Driving assistance systems

Rain and light sensor (RLS)


The rain and light sensor (F8X) is located at the
front under the windshield in the center.
The rain and light sensor records the current
ambient light intensity and the degree of wetting of
the windshield. It uses this information to generate
a corresponding signal which is needed to control
the following functions:
Exterior lights
Interior lights
Intermittent wipe of wiper system

B81 Rain and light sensor

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W54.21-1429-00

The outside mirror with maneuvering position on


the front passenger side (F6L) is available for all
vehicles.
To improve visibility of the semitrailer/trailer,
particularly during reverse maneuvering, the main
mirror on the passenger side can be moved into an
optimal maneuvering position (approx. 10
outwards) by pressing the button (1).
The desired maneuvering position can be adjusted
further via the mirror rocker switch because each
different seat position can require a different
maneuvering position.
The function is terminated under the following
conditions:

Driving assistance systems

Outside mirror with maneuvering position

W88.79-1006-00

Outside mirror with maneuvering position

After 2 minutes elapse


By pressing the button (1) again
When a vehicle speed of v > 10 km/h is
exceeded

W54.25-1193-00

Outside mirror maneuvering position button (1)

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Comfort

Heating and climate control


The new Actros features an air-regulated heating,
ventilation and climate control system.

The air distribution system of the heating, ventilation and climate control system includes:

The temperature is not adjusted by means of a


water regulating valve but by mixing cold and warm
air with a blend air flap. This produces an immediate
response and accurate adjustability.

A defroster duct with exhaust vents located at


uniform intervals along the windshield
Four horizontally/vertically adjustable and
closable air vents in the instrument panel. The
right-hand driver air vent with diffuser function.
Targeted air feed to the side windows through
multi-range air vents
Air vents for the driver footwell located on both
sides and next to the steering column
Two air vents for the front passenger footwell

All of the components, except the manual heater,


are networked with each other via CAN bus and
diagnosis-capable.
For the first time, an air vent which distributes the
air indirectly and without draft within the cab by
means of a diffuser function has also been used.

W83.30-1212-00

Air distribution

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All air flaps of the heating, ventilation and climate


control system are operated by electric motors. The
max. heat output is 12.0 kW and the max. cooling
output is 9.0 kW.
The interior temperature sensor is located in the
stowage compartment above the windshield.
The following variants of the heating, ventilation
and climate control system are available:
Heater with manual temperature control
Heater with automatic temperature control in
combination with auxiliary water heater
(D6M/D6N)
Air conditioning with automatic temperature
control (D6F)
Automatic air conditioning with fully automatic
temperature and air distribution control, with
sun sensor and air quality sensor for automatic
fresh air/recirculated air control (D6G)

The automatic air conditioning is characterized by


the following features:

Comfort

Heating and climate control

All functions (blower, air distribution,


temperature) are adjusted to the ambient
conditions fully automatically
In addition to the interior temperature sensor,
an air outlet temperature sensor improves the
control quality of the air conditioner
Using a sun sensor, the intensity of the incoming
solar radiation is incorporated for control of the
outlet air temperature
The air quality sensor detects increased concentration of CO and NOx in the outside air and
automatically switches to air recirculation mode
until the quality of the outside air is adequate
again

Assignment of heating, ventilation and climate control systems to cab

Manual
heater

Air conditioning

Automatic
air cond.

Stationary
air cond.

D6F

D6G

D6H

Cab width 2.3 m

Standard

SA

SA

SA

Cab width 2.5 m

SA

Standard

SA

SA

Auxiliary
water heater
Cab

Auxiliary
water heater
Cab
and engine

Residual heat
utilization

D6M

D6N

D6I

Cab width 2.3 m

SA

SA

SA

Cab width 2.5 m

SA

SA

SA

Code

Code

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Comfort

Heating and climate control


A/C operating units

W83.40-1026-00

Air conditioning with automatic temperature control (D6F)

W83.40-1028-00

Automatic air conditioning with fully automatic temperature and air distribution control, with sun sensor and air
quality sensor for automatic fresh air/recirculated air control (D6G)

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Auxiliary water heater, general information

Stationary air conditioner (D6H)

The auxiliary water heater (SA) is installed under the


cab floor on the left-hand side and is insulated from
vibrations. The auxiliary water heater can be operated via the operating unit for the heater/air conditioning or the auxiliary heater button in the vicinity
of the lower bed.

The design of the stationary air conditioner (SA) has


been modified significantly and consists primarily of
two assemblies:

Auxiliary water heater, cab (D6M)


The auxiliary water heater is exclusively intended
for heating the heating circuit for the cab. The
maximum heat output is 3.8 kW.
Auxiliary water heater, cab and engine (D6N)
The auxiliary water heater is intended for heating
the heating circuit for the cab and engine. The
maximum heat output is 9.1 kW.
Residual heat utilization (D6I)
The residual heat pump is installed under the cab on
the driver side and is insulated from vibrations. On
vehicles with code (D6G) Automatic air conditioning
or code (D6N) Auxiliary water heater for cab and
engine, the residual heat pump is installed as standard. Depending on the outside temperature and
coolant temperature, the residual heat pump can be
operated for up to 2 hours.

Comfort

Heating and climate control

Cold reservoir with stationary air conditioner


solenoid valve and recirculation pump for
refrigerant
Refrigeration unit with control unit, blower, heat
exchanger, dust filter and air ducts
The cold reservoir is installed underneath the cab
on the left-hand side instead of the tool box. The
refrigeration unit is attached to the rear panel of the
cab.
The two assemblies are connected by two flexible
lines in which a water/glycol mixture circulates as
refrigerant. The refrigerant is the same as the
coolant used for the engine cooling system. The
cold reservoir can be charged by the refrigerant
compressor during driving operation.

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Comfort

Heating and climate control

W83.30-1213-00

Stationary air conditioner


1
2
3
4
5
6
7
8

Cold reservoir
Dust filter
Blower
Reservoir
Heat exchanger
Exhaust vents
Intake duct
Cab forced ventilation

A14

Stationary air conditioning (IAC) control unit

Stationary air conditioner cold reservoir


1
10
11
12

Cold reservoir
Check valve
Service connection, fill/empty
Cold reservoir expansion valve

A41b1 Stationary air conditioner cold reservoir


temperature sensor
A41m1 Stationary air conditioner cold reservoir
coolant pump
A41y1 Stationary air conditioner cold reservoir
solenoid valve
W83.30-1214-00

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New radio generation


The radio in the new Actros forms part of the Truck
Control Center (TCC). It is integrated optimally and
ergonomically into the dash support. In addition to
the increased operating comfort, this also creates
an important safety advantage: the driver's view is
not distracted from the road as much when operating the radio. All radio units are supplied by Bosch
and are equipped with a USB interface (standard on
the long cabs).

The radio including navigation system, which is fully


integrated in the TCC, is an exciting new feature.
The navigation information is displayed both on the
17.8 cm (7") color display and on the multifunction
display.

Radio, with USB connection (J2E)

CD radio (J2A)

FM/AM single tuner with RDS-EON and 2 x 6


station presets
Front mini-USB connection
AUX connection, e.g. for MP3 players at front
and rear
Telephone muting
Output power 2 x 20 W
One-line segment display

Audio and communications

Telematics

Same features as J2E, plus


CD player (MP3 and WMA-capable)

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Audio and communications

Telematics
Bluetooth CD radio (J2B)

Comfort Bluetooth CD radio (J2C)

Same features as J2A, plus

Same features as J2B, plus:

12.2 cm (5") monochrome display


2 x 10 station presets
Bluetooth interface with hands-free system,
audio streaming
Integrated hands-free microphone
12-button keypad for telephone operation
Output power 4 x 20 W

Preinstallation for mobile phone charging cradle


(1) with external antenna connection

Comfort Bluetooth radio/navigation system


(J2D)

Same features as J2C, plus:


High-resolution 17.8 cm (7) color display
Navigation: preinstalled navigation data for
Europe including truck restrictions
Navigation display on instrument cluster
Destination memory/address book
Dynamic route guidance
Visual and acoustic driving recommendations
Video input e.g. for reversing camera
Video functions for
mpeg1/mpeg2/divX/SVCD/DVD video formats
Digital operator's manual
8 GB hard disk

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Mini-USB connection

Speakers

The mini-USB connection on the radio can be used


to charge the battery of an additional device e.g. an
MP3 player. The radio can be operated in different
ways:

The sound is output via two broadband speakers in


the doors and a center speaker (J2I) in the stowage
compartment above the windshield on vehicles with
standard equipment. The center speaker is
designed as a dual coil speaker. The first coil is used
to play music, sound and voice from the radio while
the second coil is used as a vehicle information
source and performs the following acoustic functions irrespective of whether or not the radio is
switched on:

All functions can be controlled on the radio unit


itself; the selected radio station or CD is displayed in plain text on the radio display
Only the "Volume +/-" and "Track/Station"
functions can be operated via the "Radio" button
on the cab rear panel
The functions "Switch on/off", "Source", "Volume +/-", "Mute" and "Track/Station" can be
operated via the new multifunction key.
Depending on the radio unit, the following functions can be activated via the steering wheel
buttons:
- Volume +/- Change station/SCAN
- Select CD/Track/Music Browser
- Telephone control/phone book
- Change source
- Select CD track

Audio and communications

Telematics

Warning buzzer
Feedback after completion of gear-shift operations
Turn signal indicator sounds
The second coil of the center speaker is actuated by
the instrument cluster (not on vehicles with J1A
because here there is a separate speaker), which
receives the input signals and generates the
different sounds in accordance with their priority.

In the "Audio" menu item, the multifunction display


shows plain text about the selected radio station or
USB/CD activities. When operating via the steering
wheel buttons, every change is displayed for easier
navigation.
Upon request, the radio can be omitted on vehicles
where it is standard equipment with code (J9Y). If
no radio is installed at the plant, no speakers and no
wiring harness are supplied either. The antenna is
routed into the DIN slot without wiring.
On vehicles with 12 V radio preinstallation (J9F) for
retrofitting, the connecting cable and the antenna
lines are routed into the DIN slot in the TCC. The
code includes the voltage converter 24 V/12 V, 10
A (E3A), but no wiring for the center speaker.

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Audio and communications

Telematics
Code (J2K) Speakers, 2-way system, contains the
following:
2 woofers in the doors (160 mm dia.)
1 center speaker in the stowage compartment
above the windshield
2 tweeters in the A-pillars

The Sound system (J2J) provides an even better


sound experience. Here, 2 additional broadband
speakers in the bed area and an active subwoofer in
the stowage box ensure optimal sound distribution
within the cab.

Further communication features available as


special equipment:
CB radio
Code (J9A): Preinstallation for retrofitting of CB
radio, including voltage converter 24 V/12 V, 10 A
(E3A) and antenna.
Code (J2Z): The CB mobile radio system includes
the 12 V voltage converter (18 A), a microphone
and the CB radio antenna and represents a highquality, all-in-one ex factory solution for all vehicles.

Communications interface (COM) (E4A)


The communications interface is a technical prerequisite for connecting and operating an on-board
computer (e.g. FleetBoard) via the CAN data bus
of the vehicle. Vehicles with FleetBoard packages
(code J3A, J3C, J3D, J3E, J3J, J9C, J3M) are therefore
equipped with (E4A) as standard.
The communications interface, which allows an onboard computer to be connected to the vehicle,
makes it possible for the dispatching office to
remotely access vehicle data through digital data
transfer e.g. for trip planning, transport capacity
planning, maintenance scheduling etc.
Previously integrated in the parameterizable special
module (PSM) control unit, the communications
interface now forms part of the central gateway
(CGW) control unit.

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Interface, fleet management system,


FMS 2.0 (E4B)

FMS standard 3.0 will be available as of October


2011 and contains further data.

Code E4B contains a standardized telematics interface (COM), which is defined by fleet management
system standard 2.0 (FMS standard 2.0).

E4B Is only available in combination with the


telematics preinstallation (J9B).

The interface converts the standardized CAN data


into the standardized SAE J1939 format and
forwards it to the respective fleet management
system. The FMS standard was defined jointly by
various European vehicle manufacturers (Daimler,
DAF Trucks, IVECO, MAN, Scania and Volvo). As
such, different fleet management systems can use
and evaluate the vehicle data obtained from vehicles of the aforementioned manufacturers without
problem and independently.
Depending on the vehicle equipment, the following
data can be accessed in FMS standard 2.0 (valid as
of October 2010):

Vehicle speed
Accelerator pedal position
Cruise control/clutch/power take-off status
Brake light switch
Total fuel consumption
Fuel tank fill level
Engine speed
Axle load of individual axles
Gross vehicle weight
Total engine operating hours
Vehicle identification number (VIN)
Software identification number
Total mileage of vehicle (km)
Next maintenance service
Tachograph information
Engine coolant temperature
FMS standard information
Tachograph: speed, driver card, driver status,
direction of travel, exceeding of speed limits

The retrofit allows parallel operation i.e. an external


telematics system can be connected to the FleetBoard vehicle computer and it will find the FMS
interface previously activated via FleetBoard at
the request of the customer. The FleetBoard
vehicle computer is delivered from the plant with
the FMS interface deactivated as standard.

Audio and communications

Telematics

The telematics preinstallation (J9B) contains a


GSM/GPS antenna on the cab roof and wiring up to
the DIN slot in the stowage compartment above the
windshield. With the telematics preinstallation, an
external navigation or telematics device can be
subsequently retrofitted.
The preinstallation for FleetBoard (J9C) contains
additional features compared to E4B and more
information can be accessed than via the standardized telematics interface. It contains:
The mechanical/electrical preinstallation
(antennas and lines for the FleetBoard components within the direct field of view/reach
CAN connection in accordance with ISO11898
Exclusive access to all CAN and diagnostic data
for FleetBoard telematics

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Audio and communications

Telematics
Antennas

Tachograph

Through the use of antenna splitters, one


GSM/GPS antenna is sufficient to supply the navigation unit and FleetBoard. Depending on the
number of terminals installed, a double or triple
splitter is used; these both have the same design
and are installed in the same position.

The tachograph records driving times and rest


periods for the driver and co-driver. It is available in
modular or digital versions and in the following variants:
Code (J1R):
Digital tachograph, EC, rpm, ADR
Code (J1K):
Tachograph, 1 day + 2 driver, modular
Code (J1P):
Tachograph, 1 day + 2 driver, up to 140 km/h
(modular)
The digital tachograph (J1R) is available from the
suppliers VDO (J1S) or Stoneridge (J1T).
A calibration system (G5Z) is required to put the
modular tachograph into operation; this adjusts the
speed and odometer readings to the vehiclespecific situation. It takes the tire size and rear axle
ratio into account for this purpose.
In the case of countries without regulations
governing working times or vehicles which are not
subject to monitoring of working times, the
tachograph can also be omitted (code (J1Z)
Speedometer, omission of tachograph).

i Note

W82.62-1021-00

Antennas (example, equipment-dependent)


1
2
3
4

134

Radio/telephone antenna
GSM/GPS antenna for TollCollect
GSM/GPS antenna
CB radio antenna

There is no special calibration requirement for the


tachograph (TCO). As of October 2011, the
customer can enter the license plate number once
in the TCO themselves without a workshop card or
workshop tool.

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FleetBoard vehicle computer (J3A/J3M)


FleetBoard is a telematics-supported Internet
service for modern vehicle, fleet and transport
management which supports fleet managers,
drivers and dispatching staff. The data transfer
between the vehicle and FleetBoard takes place
via mobile radio(GSM/GPRS).
On the new Actros, the FleetBoard TiiRec vehicle
computer is installed as standard and forms the
basis for the FleetBoard vehicle management
system.

Audio and communications

Telematics

Features:
Technical data for modern commercial vehicles
with FMS interface
Integrated GSM/GPRS modem and GPS
receiver
Driver recognition with FleetBoard Driver Card
Online update feature
Travel records
Telediagnosis
Standard DIN slot
Individual customization of messages

W82.87-1000-00

FleetBoard vehicle computer

FleetBoard DispoPilot, mobile (J3C)


The FleetBoard DispoPilot, mobile is a sturdy,
shock-proof handheld device. It is used for communication between the driver, vehicle and dispatch
office and is installed in the center stowage
compartment of the dash support.
Features:
9.9 cm (3.9") color display with touchscreen
2D imager for barcode scanning and loading list
comparison
Recording and transmission of electronic signatures
Connection to vehicle management system and
time management system (in combination with
FleetBoard TiiRec)
Europe-wide communication between driver and
dispatch staff
Positioning and mapping
Remote software update

W82.87-1001-00

FleetBoard DispoPilot, mobile

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135

Audio and communications

Telematics
Fleetboard DispoPilot.guide (J3E)
The FleetBoard DispoPilot.guide is a fixed installation variant with large screen and, as the cost-efficient entry-level model, offers the following
features:
17.8 cm (7") color display with touchscreen
Connection to vehicle management system and
time management system (in combination with
FleetBoard TiiRec)
Europe-wide communication between driver and
dispatch staff
Positioning and mapping
Both DispoPilot devices (J3C and J3E) incorporate a
navigation function with the following features:
Navigation for over 25 European countries
Destination transfer from the order or manual
destination entry e.g. via zip code
Storage of geocoded addresses or current location as destination, stopovers
Stepless zoom in map view (Europe down to
road view)
General map and display of route list
Full screen mode
Operating comfort and ergonomic design
through modern user interface
Lane Assistant
Truck attributes:
height, length, width and weight
Truck-specific special destinations e.g. workshops
Calculation of arrival time with truck speed profile
Notification of dispatch staff if vehicle delayed
Available for Germany, France, Benelux countries, Great Britain

W82.87-1002-00

FleetBoard DispoPilot.guide
A View of touchscreen
B View of side

i Note
To allow customers to familiarize themselves with
all of the benefits of telematics-supported vehicle
management in detail, they are given the option of
testing FleetBoard free of charge for four
months: during this test phase, the first month
serves as a reference month during which important data such as fuel consumption are recorded
precisely.
At the end of the 4-month test phase, the
customer can decide whether they wish to
continue benefitting from the economic benefits
of FleetBoard at their company.

136

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Claw wrench

Special tools

Engine

Use Claw wrench for removing and installing the


water sleeve of the injector.

Special tool W 470 589 00 07 00


number

W58.20-1011-00

FG 07
Set B
Category Mercedes-Benz Truck Special Operations

Drift

Use Drift for fixing the crankshaft at TDC via the


flywheel ring gear.

Special tool W 470 589 00 15 00


number

W58.20-1012-00

FG 05
Set B
Category Mercedes-Benz Truck Basic Operations

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137

Special tools

Engine
Measuring bridge

Use Measuring bridge for measuring the piston


projection.

Special tool W 470 589 00 31 00


number

W58.20-1013-00

FG 03
Set C
Category Mercedes-Benz Truck Special Operations

Adapter

Use Adapter for checking compression via the


injector bore.

Special tool W 470 589 00 91 00


number
FG 01
Set B
Category Mercedes-Benz Truck Basic Operations

138

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W58.20-1014-00

Cover

Special tools

Engine

Use Cover for covering the camshaft sprockets


with the cylinder head cover removed.

Special tool W 470 589 00 98 00


number

W58.20-1015-00

FG 05, 07
Set B
Category Mercedes-Benz Truck Special Operations

Adjustment tool

Use Adjustment tool for adjusting the timing drive


on gear 3.

Special tool W 470 589 01 21 00


number

W58.20-1016-00

FG 05
Set C
Category Mercedes-Benz Truck Special Operations

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139

Special tools

Engine
Locating tool

Use Locating tool for fixing the crankshaft at TDC


when mounting the gear drive.

Special tool W 470 589 01 23 00


number

W58.20-1017-00

FG 03
Set B
Category Mercedes-Benz Truck Special Operations

Extraction tool

Use Extraction tool for pulling injectors


out of the cylinder head.

Special tool W 470 589 01 33 00


number
FG 07
Set B
Category Mercedes-Benz Truck Basic Operations

140

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W58.20-1018-00

Guide pin

Special tools

Engine

Use Guide pin for guiding the cylinder head during


assembly.

Special tool W 470 589 01 61 00


number

W58.20-1019-00

FG 01
Set C
Category Mercedes-Benz Truck Special Operations

141-pin adapter cable

Use Adapter cable for diagnosing the diesel injection system and Common-Rail system and for
connecting a vehicle transfer control unit.

Special tool W 470 589 01 63 00


number

W58.20-1020-00

FG 07
Set B
Category Mercedes-Benz Truck Basic Operations

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141

Special tools

Engine
Test adapter

Use Test adapter for determining the return flow


at the pressure booster, rail and injectors.

Special tool W 470 589 02 21 00


number

W58.20-1021-00

FG 07
Set B
Category Mercedes-Benz Truck Basic Operations

Puller

Use Puller for pulling off the camshaft and main


bearing bridges.

Special tool W 470 589 02 33 00


number
FG 03
Set C
Category Mercedes-Benz Truck Special Operations

142

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W58.20-1022-00

Assembly tool

Special tools

Engine

Use Assembly tool for mounting the rear radial


shaft sealing ring on the crankshaft output.

Special tool W 470 589 02 43 00


number

W58.20-1023-00

FG 03
Set B
Category Mercedes-Benz Truck Special Operations

Assembly tool

Use Assembly tool for mounting the piston in the


cylinder barrel.

Special tool W 470 589 02 59 00


number

W58.20-1024-00

FG 03
Set C
Category Mercedes-Benz Truck Special Operations

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143

Special tools

Engine
Socket

Use Socket for installing and removing the oil


thermostat.

Special tool W 470 589 03 09 00


number

W58.20-1025-00

FG 18
Set B
Category Mercedes-Benz Truck Basic Operations

Template

Use Template for positioning the camshafts at


TDC.

Special tool W 470 589 03 23 00


number
FG 05
Set B
Category Mercedes-Benz Truck Special Operations

144

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W58.20-1026-00

Adjustment tool

Special tools

Engine

Use Adjustment tool for adjusting the Jake Brake.

Special tool W 470 589 04 23 00


number

W58.20-1027-00

FG 14
Set B
Category Mercedes-Benz Truck Special Operations

Mounting tool

Use Mounting tool for pulling O-rings onto injectors.

Special tool W 470 589 04 33 00


number

W58.20-1028-00

FG 07
Set B
Category Mercedes-Benz Truck Basic Operations

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145

Special tools

Engine
Removal and installation tool

Use Removal and installation tool for remove and


installing the entire engine.

Special tool W 470 589 04 62 00


number

W58.20-1029-00

FG 01
Set B
Category Mercedes-Benz Truck Basic Operations

Removal and installation tool

Use Removal and installation tool for installing


and removing the cylinder liners and for
measuring the liner projection.

Special tool W 470 589 05 33 00


number
FG 03
Set C
Category Mercedes-Benz Truck Special Operations

146

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W58.20-1030-00

Valve tool kit

Special tools

Engine

Use Valve tool kit for removing and installing the


valve springs, incl. puller and drift for
mounting the valve stem seal.

Special tool W 470 589 05 61 00


number

W58.20-1031-00

FG 05
Set C
Category Mercedes-Benz Truck Special Operations

Leak tester

Use Leak tester for leak testing the AGR cooler

Special tool W 470 589 07 91 00


number

W58.20-1032-00

FG 09
Set B
Category Mercedes-Benz Truck Basic Operations

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147

Special tools

Engine
Locating tool

Use Locating tool for fixing fuel pump and air


compressor in place when
removing/installing the drive gear.

Special tool W 470 589 08 40 00


number

W58.20-1033-00

FG 07, 13
Set B
Category Mercedes-Benz Truck Basic Operations

Locating tool

Use Locating tool for fixing the rocker arms on the


rocker shaft during removal and installation.

Special tool W 470 589 09 40 00


number
FG 05
Set B
Category Mercedes-Benz Truck Special Operations

148

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W58.20-1034-00

Adapter

Special tools

Engine

Use Adapter for fuel pressure measurement at


SAE connection of fuel filter module.

Special tool W 470 589 10 91 00


number

W58.20-1035-00

FG 07
Set B
Category Mercedes-Benz Truck Basic Operations

Adapter

Use Adapter for leak testing the fuel filter module.

Special tool W 470 589 11 91 00


number

W58.20-1036-00

FG 07
Set B
Category Mercedes-Benz Truck Basic Operations

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149

Special tools

Engine
Stop plug

Use Stop plug for sealing the rail connections


during testing work.

Special tool W 470 589 12 91 00


number

W58.20-1037-00

FG 01, 07
Set B
Category Mercedes-Benz Truck Basic Operations

Mount

Use Mount for adapting the DPF mount to a standard forklift.

Special tool W 470 589 04 31 00


number
FG 14
Set B
Category Mercedes-Benz Truck Basic Operations

150

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W58.20-1038-00

Mount

Special tools

Engine

Use Mount for removing and installing the diesel


particulate filter (DPF).

Special tool W 470 589 01 62 00


number

W58.20-1039-00

FG 14
Set B
Category Mercedes-Benz Truck Basic Operations

Lifting device

Use Lifting device for removing and installing the


radiator module.

Special tool W 963 589 00 62 00


number

W58.20-1040-00

FG 20
Set B
Category Mercedes-Benz Truck Basic Operations

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151

Special tools

Transmission
Lifting eye

Use Lifting eye for removing the range group.

Special tool W 715 589 00 40 00


number
FG 26
Set C
Category Mercedes-Benz Truck Special Operations

152

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W58.20-1041-00

Mounting device

Special tools

Transmission

Use Mounting device for pressing on main shaft


bearing (rear)

Special tool W 715 589 02 43 00


number

W58.20-1042-00

FG 26
Set C
Category Mercedes-Benz Truck Special Operations
Note In combination with:
- W 715 589 13 33 00 Puller
- W 715 589 15 34 00 Hydraulic cylinder
- W 715 589 10 34 00 Adapter
- W 715 589 11 34 00 Adapter
- W 715 589 12 34 00 Adapter
- W 652 589 00 33 21 Hand pump
- W 652 589 00 33 23 Hydraulic hose

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153

Special tools

Transmission
Puller

Use Puller for removing and installing the piston of


the splitter group

Special tool W 715 589 03 07 00


number

W58.20-1043-00

FG 26
Set C
Category Mercedes-Benz Truck Special Operations

Holding device

Use Holding device for fixing the shift fork in place


with the splitter group

Special tool W 715 589 07 31 00


number
FG 26
Set C
Category Mercedes-Benz Truck Special Operations

154

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W58.20-1044-00

Drift

Special tools

Transmission

Use Drift for installing the radial shaft sealing ring


of the output shaft into the rear section of the
transmission housing

Special tool W 715 589 08 15 00


number

W58.20-1045-00

FG 26
Set B
Category Mercedes-Benz Truck Basic Operations

Puller

Use Puller for pulling off the rear section of the


transmission housing and the gear for 1st
gear.

Special tool W 715 589 13 33 00


number

W58.20-1046-00

FG 26
Set C
Category Mercedes-Benz Truck Special Operations
Note In combination with:
- W 715 589 15 34 00 Hydraulic cylinder
- W 715 589 10 34 00 Adapter
- W 715 589 11 34 00 Adapter
- W 715 589 12 34 00 Adapter
- W 652 589 00 33 21 Hand pump
- W 652 589 00 33 23 Hydraulic hose

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155

Special tools

Transmission
Removal bolts

Use Removal bolts for removing the range group

Special tool W 715 589 14 33 00


number

W58.20-1047-00

FG 26
Set C
Category Mercedes-Benz Truck Special Operations
Note The set contains 3 of each bolt

Holding device

Use Holding device for holding the shift rails in the


neutral position with the transverse shift gate
removed.

Special tool W 715 589 24 63 00


number
FG 26
Set C
Category Mercedes-Benz Truck Special Operations

156

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W58.20-1048-00

Cover

Special tools

Transmission

Use Cover for protecting the wiring harnesses


during removal and installation of the transmission

Special tool W 715 589 25 63 00


number

W58.20-1049-00

FG 26
Set B
Category Mercedes-Benz Truck Basic Operations

Support plate

Use Support plate for removing the entire transmission with an inspection pit lift

Special tool W 715 589 26 63 00


number

W58.20-1050-00

FG 26
Set B
Category Mercedes-Benz Truck Basic Operations
Note In combination with car transmission plate
(see GOTIS chapter A, design group
25/35/49, topic 02.0)

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157

Annex

Abbreviations

ABS

BESO

Antilock brake system

Battery Emergency Switch Off

ACM

CAD

Aftertreatment Control Module

Computer Aided Design

ADR

CAN

Accord europen relatif au transport international des


marchandises Dangereuses par Route
(European Agreement Concerning the International
Carriage of Dangerous Goods by Road)

Controller Area Network

AGR

APCRS

ASA

Central gateway control unit


CLCP

Additional Steering Axle


ASH

Chassis Level Control Panel


CLCS

Body floor height

Chassis Level Control System

ASIC

COM

Application System Integrated Circuit


ASR

Communication Interface
CPC

Acceleration skid control

158

Central Data Storage


CGW

Amplified Pressure Common Rail System

Anti-theft alarm system

Common Axle Platform


CDS

Exhaust gas recirculation (EGR)

ATA

CAP

Common Powertrain Controller


CPCA
Concentric Pneumatic Clutch Actuator

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DCMD

ENA

Door Control Module Driver

Single-tired trailing axle

DCMP

ESC

Door Control Module Passenger

European Stationary Cycle

DNA

ESP

Twin-tired trailing axle

Electronic Stability Program

DOHC

ETC

Double Overhead Camshaft

European Transient Cycle

DPF

FBS

Diesel Particulate Filter

Drive authorization system (DAS)

EAPU

FHS

Electronic Air-Processing Unit

Cab

EBS

FMS

Electronic Brake Control

Fleet Management System

ECE

GGVS

Economic Commission for Europe

Regulations for the Transportation of Hazardous


Goods

Annex

Abbreviations

EEV
Enhanced Environmentally Friendly Vehicle

HA
Rear axle (RA)

EIS
HMI

Electronic Ignition Switch

Human Machine Interface


ELR
European Load Response Test

HVAC
Heating Ventilation Air Conditioning

EMV
Electromagnetic compatibility (EMC)

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159

Annex

Abbreviations

IAC

PTO

Independent Air Conditioning


(stationary air conditioner)

Power take-off
NLA

IBS

Trailing axle

Battery sensor
OBD
ICUC

On-Board Diagnosis

Instrument Cluster Unit Common


OM
ITH

Diesel engine

Independent Truck Heating


(truck auxiliary heater)

Printed Circuit Board

LED

PG

Light Emitting Diode

Product Group

LIN
Local Interconnect Network

PSM

Motor Control Module

Parameterizable Special Module

MIL
Malfunction Indicator Lamp

Maintenance System
MSF

PM
Particulate Mass

MCM

MS

PCB

PWM
Pulse Width Modulation
QVGA
Quarter Video Graphics Array

Modular switch panel

160

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RCM

SRS

Retarder Control Module

Supplemental Restraint System

RDF

SWR

Radar Front End

Secondary Water Retarder

RLS

SZF

Rain and light sensor

Semitrailer tractor

SA

TCC

Special equipment

Truck Control Center

SAS

TCM

Steering wheel angle sensor

Transmission Control Module

SCA

TFT

Sensor and Actuator Module, Cabin

Thin Film Transistor

SCH

TPM

Sensor and Actuator Module, Chassis

Tire Pressure Monitoring System

SCR

UDS

Selective Catalytic Reduction

Unified Diagnostic-Services

SMS

VLA

Short Message Service

Leading axle

Annex

Abbreviations

VRDU
Video and Radar Decision Unit
(driver assistance system control unit)

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161

Annex

Index

A/C operating units . .


AdBlue tank . . . . .
Aerodynamics . . . . .
Air distribution . . . . .
Air guide . . . . . . . .
Air suspension . . . . .
Alternator . . . . . . . .
Ambiance illumination .
Ambient illumination .
Antennas . . . . . . . .
Auxiliary water heater .

. . . . . . . . . . . . . . . 126
. . . . . . . . . . . . . . . .38
. . . . . . . . . . . . . . . .19
. . . . . . . . . . . . . . . 124
. . . . . . . . . . . . . . . .19
. . . . . . . . . . . . . . . .62
. . . . . . . . . . . . . . . 104
. . . . . . . . . . . . . . . 111
. . . . . . . . . . . . . . . 110
. . . . . . . . . . . . . . . 134

DispoPilot, mobile
DispoPilot.guide .
Vehicle computer
Frame concept . .

.
.
.
.

.
.
.
.

.
.
.
.

Frame heights . . . . . .
Frame track widths . . .
Front axle . . . . . . . .
Front fog lamps . . . . .
Front radar sensor (RDF)

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

135
136
135
. 56

. . . . . . . . . . . . . . . 59
. . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . 66
. . . . . . . . . . . 107, 108
. . . . . . . . . . . . . . 120

. . . . . . . . . . . . . . . 127

B
Backup warning system
Battery sensor (IBS) . .
Beds . . . . . . . . . . .
Bi-xenon headlamps . .

Halogen headlamps . . . . . . . . . . . . . . 106, 107


. . . . . . . . . . . . . . . 110
. . . . . . . . . . . . . . . 103

. . . . . . . . . . . . . . . .87

Leading axle . . . . . . . . . . . . . . . . . . . . . . 69
LED daytime running lights . . . . . . . . . 107, 108
Level control . . . . . . . . . . . . . . . . . . . . . . 65

. . . . . . . . . . . . 106, 107

C
Cab dimensions . . . . . . . . . .
CAN data bus system . . . . . . .
CB radio . . . . . . . . . . . . . . .
Clearance lamp . . . . . . . . . .
Communications interface (COM)
Coolant pump . . . . . . . . . . .
Cooling air control . . . . . . . . .
Cooling module . . . . . . . . . .
Cornering lights . . . . . . . . . .
Coupling point heights . . . . . .
Crawl function . . . . . . . . . . .

. . . . . . . . . .79

. . . . . . . . . 102

Multifunction control lever . . . . . . . . . . . . . . 44

. . . . . . . . . 132
. . . . . . . . . 110
. . . . . . . . . 132
. . . . . . . . . .36
. . . . . . . 20, 35
. . . . . . . . . .34
. . . . . . . . . 107
. . . . . . . . . .59
. . . . . . . . . .46

E
EcoRoll . . . . . . . . . . . . . . . . . . . . . . . . .46

162

Fleet Management System . . . . . . . . . . . . 133


FleetBoard

O
On-Board Diagnosis (OBD) . . . . . . . . . . . . . . 29

P
Parking brake . . . . . . . . . . . . . . . .
Performance graph . . . . . . . . . . . . .
Pneumatic central clutch release bearing
Power socket . . . . . . . . . . . . . . . .
Product groups

. . . . . 51
. . . . . 33
. . . . . 48
. . . . 105

Payload . . . . . . . . . . . . . . . . . . . . . . . 10
Volume . . . . . . . . . . . . . . . . . . . . . . . 10

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Annex

Index

Radio . . . . . . . . . . .
Rear axle . . . . . . . . .
Rear lamps . . . . . . . .
Residual heat utilization
Rocking the vehicle free

. . . . . . . . . . . . . . 129
. . . . . . . . . . . . . . . 68
. . . . . . . . . . . . . . 110
. . . . . . . . . . . . . . 127
. . . . . . . . . . . . . . . 46

S
Seat variants . . . . . . . .
Side marker lamp . . . . .
Smoke alarm . . . . . . . .
Sockets . . . . . . . . . . .
SoloStar concept . . . . .
Speakers . . . . . . . . . .
Stationary air conditioner
Steering

. . . . . . . . . . . . . . 85

Tachograph . . . . . .
Thermal management
Trailing axle . . . . . .
Transfer rate . . . . .
Transmission cooling .
Transmission modes .
Transmission ratios .
Truck Control Center .

. . . . . . . . . . . . . . . 134
. . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . 69
. . . . . . . . . . . . . . . 102
. . . . . . . . . . . . . . . . 49
. . . . . . . . . . . . . . 44, 45
. . . . . . . . . . . . . . . . 43
. . . . . . . . . . . . . . . 129

. . . . . . . . . . . . . 110
. . . . . . . . . . . . . . 88

. . . . . . . . . . . . . 105

Underfloor paneling . . . . . . . . . . . . . . . . . 19
USB connection . . . . . . . . . . . . . . . . . . 131

. . . . . . . . . . . . . . 84
. . . . . . . . . . 131, 132
. . . . . . . . . . . . . 127

1-circuit . . . . . . . . . . . . . . . . . . . . . . . 73
with additional steered axle . . . . . . . . . . . . . 74

Suspension
Front axle . . . . . . . . . . . . . . . . . . . . . . 61
Rear axle . . . . . . . . . . . . . . . . . . . . . . 64
Suspension seat with massage function . . . . . . 84

Introduction of the New Truck Generation - The New Actros (Model 963) i
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163

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Introduction of the New Truck GenerationThe New Actros (Model 963)

Daimler AG, GSP/OI, HPC R 822, D-70546 Stuttgart


Order No. 6517 1259 02 - HLI 000 000 02 77 Printed in Germany 09/11

Introduction of the New Truck


Generation
The New Actros (Model 963)
Introduction into Service Manual