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Truck•Complete Vehicle <> ACTROS •
Models 930-934 • Basic Training
Truck•Complete Vehicle
ACTROS Models 930-934
Basic Training
As at 01/04
This document is intended solely for use in training and is not subject to regular updating.
Printed in Germany Note:

ã 2004 Copyright DaimlerChrysler AG The term »employees« does not imply any
preference of gender and incorporated male
Publisher: Global Training and refers to maler and female employees
This document with all its sections is protected under the laws of copyright. Its use for any alike.
purpose whatsoever requires the prior written consent of DaimlerChrysler AG. This applies in
particular to its reproduction, distribution, modification, translation, recording on microfilm or
storage and/or processing in electronic systems, including databases and on-line services.
1511 1286 02 - 2. Edition 01.04 222 As at 01/04

Content 02.09.2004
Title Page
Foreword ..................................................................................................................................................................................................................................................1
Sequence of Training ...............................................................................................................................................................................................................................2
Vehicle/Cab Visual Inspection Learn Targets .........................................................................................................................................................................................3
Visual Inspection......................................................................................................................................................................................................................................4
Electrical System Learn Targets ............................................................................................................................................................................................................19
Electrics .................................................................................................................................................................................................................................................20
Power Distributor ...................................................................................................................................................................................................................................21
Jumpstarting...........................................................................................................................................................................................................................................22
GGVS Functions - Battery Disconnect Switch (BTS)..............................................................................................................................................................................23
Vehicle Networking Basics.....................................................................................................................................................................................................................24
Virtual Control Units, Integrated Functions ...........................................................................................................................................................................................30
Base Module (BM)..................................................................................................................................................................................................................................32
Base Module - Function .........................................................................................................................................................................................................................34
Relays and Fuses ...................................................................................................................................................................................................................................35
Central Data Memory (CDM) in the Base Module..................................................................................................................................................................................37
Trailer Socket.........................................................................................................................................................................................................................................38
Electric Circuit Diagrams .......................................................................................................................................................................................................................40
Front Module (FM) and Rear Module (RM) ............................................................................................................................................................................................42
09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

Content I 1
Front and Rear Modules - Functions......................................................................................................................................................................................................44
Base, Front and Rear Modules...............................................................................................................................................................................................................45
Instrument Cluster .................................................................................................................................................................................................................................46
Sound Module - Instrument Cluster 2002 .............................................................................................................................................................................................49
Driver Information System.....................................................................................................................................................................................................................50
Multifunction Steering Wheel.................................................................................................................................................................................................................52
Star Diagnosis (DAS)..............................................................................................................................................................................................................................56
Practical <> Instrument Cluster and On-board Diagnosis......................................................................................................................................................................60
Modular Switch Panel (MSF)..................................................................................................................................................................................................................69
Modular Switch Panel - Components.....................................................................................................................................................................................................71
Modular Switch Panel - NEW Switches..................................................................................................................................................................................................72
Modular Switch Panel and Illumination..................................................................................................................................................................................................74
Retrofitting of NEW Power and Signal Switches....................................................................................................................................................................................75
Xenon Headlamps - Design and Function NEW .....................................................................................................................................................................................77
Gas Discharge Headlamps - Design and Function.................................................................................................................................................................................79
Practical <> Modular Switch Panel and Illumination..............................................................................................................................................................................81
Power Tapping .......................................................................................................................................................................................................................................86
Plug X7 on the Base Module ..................................................................................................................................................................................................................87
Retrofitting Two-Way Radios..................................................................................................................................................................................................................88
Retrofitting Phones ................................................................................................................................................................................................................................89
Retrofitting Work Lamps ........................................................................................................................................................................................................................90
Retrofitting sidelights.............................................................................................................................................................................................................................91

Content I 2
Learn Targets <> Drive Train..................................................................................................................................................................................................................92
Engine: Model Series 500 ......................................................................................................................................................................................................................93
BR 500 Technical Features ....................................................................................................................................................................................................................95
Technical Details BR 500 in the ACTROS Model 930-934.....................................................................................................................................................................96
Performance Graph in the ACTROS Model 930-934 .............................................................................................................................................................................97
Engine: Oil Circuit ..................................................................................................................................................................................................................................98
Engine Crankshaft Seal Front and Rear BR 500 ................................................................................................................................................................................. 102
ACTROS Model 930-934 Cooling System........................................................................................................................................................................................... 103
Testing the Cooling System for Leaktightness ................................................................................................................................................................................... 104
Engine: Valve Setting .......................................................................................................................................................................................................................... 106
Valve Play Adjustment BR 500 ........................................................................................................................................................................................................... 107
Engine: Engine Brake .......................................................................................................................................................................................................................... 111
Pump-Line-Nozzle Injection System ................................................................................................................................................................................................... 114
Unit Pump: Designation and Delivery Phases..................................................................................................................................................................................... 115
PLN Injection Control.......................................................................................................................................................................................................................... 116
Fuel Circuit.......................................................................................................................................................................................................................................... 122
Fuel Prefilter with Heated Water Separator, Code K81 ...................................................................................................................................................................... 126
Telligent............................................................................................................................................................................................................................................... 127
Telligent Engine System Distribution; Exercise................................................................................................................................................................................... 128
Operating Modes on the Engine Control / Permanent Brake Control Operating Lever..................................................................................................................... 129
ACTROS Model 930-934 Drive Systems Operational Concept .......................................................................................................................................................... 131
ACTROS Model 930-934 FR Drive Functions Operating Modes......................................................................................................................................................... 132

Content I 3
Practical - Engine ................................................................................................................................................................................................................................ 133
ACTROS Model 930-934 Teaching In the Foot Throttle Actuator....................................................................................................................................................... 135
EC Actuation in DAS; Exercise ............................................................................................................................................................................................................ 136
Unit Pump Classification..................................................................................................................................................................................................................... 138
Telligent Maintenance System (WS) ................................................................................................................................................................................................... 140
Maintenance System (WS) Function Model 930-934 Actros MPII Overview...................................................................................................................................... 141
Individual and Combined Maintenance............................................................................................................................................................................................... 143
Individual Maintenance 1.................................................................................................................................................................................................................... 144
Individual Maintenance 2.................................................................................................................................................................................................................... 145
Combined Service............................................................................................................................................................................................................................... 146
Practical - Maintenance ...................................................................................................................................................................................................................... 147
TIPS - General ..................................................................................................................................................................................................................................... 152
Chassis: Steering, LS 6 BK, LS 8 BK ................................................................................................................................................................................................... 154
ACTROS Model 930 - 934 Clutches.................................................................................................................................................................................................... 157
Transmission Overview ....................................................................................................................................................................................................................... 161
Telligent Shift GSII Code GE7 ............................................................................................................................................................................................................. 164
Telligent Automatic Transmission EASII Code GE2 ............................................................................................................................................................................ 169
Telligent Transmission II, Teach-in Process and Teach-in Faults GS II ............................................................................................................................................... 173
Hydraulic-Pneumatic Transmission (HPS) Code GE3.......................................................................................................................................................................... 175
Transmission Practical ........................................................................................................................................................................................................................ 179
Learn Targets <> Towing Regulations / Telligent LC / Telligent BS................................................................................................................................................... 180
Towing Regulations ............................................................................................................................................................................................................................. 181

Content I 4
Telligent Level Control (LC): Advantages ............................................................................................................................................................................................ 183
Level Control (LC): Design .................................................................................................................................................................................................................. 184
2-Bellow Air Suspension ..................................................................................................................................................................................................................... 187
LC Operator Module Practical............................................................................................................................................................................................................. 190
Axle Load Display Practical................................................................................................................................................................................................................. 192
Disc Brake........................................................................................................................................................................................................................................... 194
Telligent Brake System BS .................................................................................................................................................................................................................. 199
Front Axle/Rear Axle Control Loops................................................................................................................................................................................................... 202
Trailer Control Control Loop ............................................................................................................................................................................................................... 203
Pneumatic Function Plans .................................................................................................................................................................................................................. 204
Telligent Brake System (BS) - Redundancy......................................................................................................................................................................................... 207
Semitrailer Tractor Pressure Limitation .............................................................................................................................................................................................. 208
Semitrailer Tractor Auxiliary Brake Valve ........................................................................................................................................................................................... 209
6 x 2 Brake Pressure Control on the Trailing Axle .............................................................................................................................................................................. 211
Brake System Practical....................................................................................................................................................................................................................... 212

Content I 5
Content I 6
Foreword 02.09.2004
“ACTROS , the new truck experience”
is the motto, under which the new ACTROS BM 930-934 is presented

to the customer.
The foreground of the vehicle development was to bring a reliable

and high-quality product on to the market.
The requirements of a modern truck are constantly increasing.

For this reason, the model refinement of ACTROS reflects the
increased demands of drivers and companies. Proven and tested
technology was the basis for continuous technical development and
implementation of the extensive technical model refinement
measures.
Furthermore, the ACTROS shows the development and

implementation of a completely new, driver-oriented interior
concept, which reflects the increased demand for comfort
and safety. GT00_10_0021_C75
The wide engine range used in the new ACTROS comes in an uprated version - with the same economy.
All this technical progress contribute to a more economy-oriented, ergonomical and comfortable handling of the vehicle and bring one thing in particular to
Europe's roads:
The opportunity of a new long distance experience.

Foreword 1
Sequence of Training 02.09.2004
1st day 2nd day 3rd day 4th day
· Greeting · Instrument cluster · Engine · Telligent level regulation
· Visual inspection on the · Multifunction steering wheel · Engine practical · Telligent level regulation
vehicle practical
· DAS Introduction · Telligent maintenance system
· Cab/design · Telligent brake system
· Instrument cluster practical · Telligent maintenance system
· Power supply on-board diagnosis practical · Telligent practical
· Vehicle networking · Modular switch panel · Steering · Brake system
· Base module · Exterior Lighting · Clutch · Final test
· Trailer Socket · Modular switch panel · Transmission

practical exterior lights
· Read circuit diagram
· Retrofitting
· Front/rear module
* In the documentation, the learn targets are described before the respective section. n

Sequence of Training 2
Vehicle/Cab Visual Inspection Learn Targets 02.09.2004
After the working through this section you can...
Vehicle visual inspection:
· assign the most important media and equipment element installation locations in the cab
· open the maintenance flap
· determine the main parts on the cab outside
· find the crash elements of the cab mounting on the vehicle
· find the installation locations of the transmission operation modules
· assign the specified parts to the installation locations on the chassis
Cab:
· name the model designation of the Actros model refinement

· describe the task of the crash elements
· name the equipment possibilities of the cab roof with galley and video system
· name the various versions of the passenger seats.
· describe special features when fitting/removing the door module

Vehicle/Cab Visual Inspection Learn Targets 3
Visual Inspection 02.09.2004
Task m To get a first impression of the Actros MPII, start with a visual inspection of the vehicle. The visual
inspection divided into 3 stations corresponding to the illustration. After approx. 30 min., a change of
stations takes place.
Cab inside
Transmission/chassis 3 2 Cab outside
P00.00-1185-11

Visual Inspection 4
Station 1 cab interior
Task 1 m Draw the installation locations of the specified parts. Note down the special features.
Lane assistant Diagnostic socket

Accoustic warning
Base module with

Steering wheel
electr. fuses
Mirror adjustment
Shelves
switch
GT68_00_0028_C81
Bunks Modular switch panel

Visual Inspection 5
Station 2 <> cab exterior
Model plate Front cab mounting

Important for technical
inquiries
Chassis/cab electr.
connector (FF) Cab rear wall
Maintenance flap lock Stowage compartments
Autonomous intelligent Headlamps

cruise control
N00.00-2607-50

Visual Inspection 6
Station 3 <> transmission/chassis
Gate module
Splitter sensor
Transmission control
control unit
Gear module
Range module
N26.10-2066-06

Visual Inspection 7
Task 2 m Draw the installation locations of the shown parts. Note down the special features.
W32.33-0024-01 GT42_10_0007_C71 W54.21-1218-11 W32.33-0025-01 Battery holder W31.00-1023-71

FA LC solenoid valve RA redundancy valve Rear module RA LC solenoid valve integral rear
2-bellow air
W54.21-1217-11 suspension GT32_33_0001_C71
Front module
GT42_10_0007_C71
FA redundancy valve Power Distributor

N31.00-2083-50 GT54_10_0023_C72

Visual Inspection 8
Model Overview
The table lists the individual model types with the corresponding vehicle versions.
ACTROS ACTROS MPII Engine Vehicle version
950 930 OM 501 LA, OM 502 LA Flat-bed vehicles

952 932 OM 501 LA, OM 502 LA Dumper vehicles
953 933 OM 501 LA, OM 502 LA Concrete mixer vehicles
954 934 OM 501 LA, OM 502 LA Semitractor trailers
Vehicle model plate (example)
Please find further information in WIS (GF00.10-W-0025-02P).

Visual Inspection 9
Cab versions
The ACTROS driver cabs
To meet the usage requirement of the various

branches and businesses, the ACTROS is available
in various cab versions.
It can thus adapt itself to the respective haulage
work. The construction of the shell as well as the
use of modern safety devices ensure a very high
degree of passive safety on all versions.
DD1 roof lower standing room 1400 mm
DD2 roof lower standing room 1560 mm
DD3 L cab lowered with lower standing
room 1400 mm
F02 cab long, single cab
F04 cab long high
F05 cab medium long
F07 cab short
F15 cab Megaspace
F18 cab Megaspace, single cab
F24 straight rear wall, all
S cab short
M cab medium
L cab long
LH cab long/high
GT60_00_0033_C11

Visual Inspection 10
Cab mounting
All cab mountings on the ACTROS model 930-934 are mounted on maintenance-free 4- point mounts. Strengthened cab mountings are available for special
operational conditions. The new cab mounting is, as usual, offered in two versions, standard and convenience mounting. The convenience mounting is,
depending on wish, delivered as steel or air suspension.
W60.80-1088-78
1 Rubber pivot bearing
2 Stabilizer bearing (rubber molecular bearing)
3 Crash element
As passive safety feature, all cab mounting versions have crash elements on each side at the front. The crash elements keep the cab on vehicle frame even when
the bolt connections or die fastening brackets are broken, on a truck-typical rear-end collision.

Exterior
· 3-piece plastic bumper (steel on · Decreased side windows and mirror

construction site vehicles) soiling
· Improved front step for window washing · Optimization of the drag coefficient
· Fender shape changed, causing a reduction
in the side wall soiling
· Reduction of door handle soiling
GT88_10_0006_C71 GT88_10_0004_C72
· Large-volume stowage compartments · Reduction spray formation through

left/right on L and LH driver cabs decreased height
· Accessible from inside and outside
GT88_60_0004_C71 GT88_10_0003_C72

Seats
Driver seat:
· Transmission control unit fastened on a foldable
bracket on the driver seat.
· New fabric covers, seat upholstery are higher.
· The backrest is wider.
Passenger seat:
The function seat is standard equipment on all cab
versions. The passenger function seat comes from a
new seat generation and has all components to
ensure sufficient safety and comfort for a
passenger: seat-integral three-point belt with seat
belt tensioner, belt force limiter, inertia reel and
integrated, padded head restraint. The new space
concept is optimally realized with the function seat
GT 91 10 0011 C81
for the passenger. If the seat is not required when
driving alone the foldable seating area (cinema-seat
principle) it provides the driver additional space and
unhindered passage to the passenger door. And the
foldable backrest offers the driver more freedom of
movement, especially when using the bed.
GT_91_10_0013_C72

Reclining seat code SC1 Reclining seat code F02, F18
GT91_10_0014_C81 GT91_10_0016_C81
The reclining seat, mounted on the passenger-side, (special equipment) for The most important equipment features:
L and MEGASPACE cabs is especially designed for the driver to relax · a horizontally forward-folding backrest (which together with the 2/3 part
(during his breaks) and the passenger (during driving). of the bed results in a level sleeping space).
· wide, comfortable armrests
For this reason the velour-upholstered seat has · separate reading lamp
· an especially wide seat cushion · 3-point seat belt on the cab-side wall (C -pillar)
· a wide backrest
· a foldable and padded armrests
· an integrated head restraint with vertically adjustable neck bolster
· a reading lamp
· a three-point belt with seat belt tensioner, belt force limiter, inertia reel

Bunks
In the new ACTROS, a new combination is used for the first time, which gives
the driver as well as the passenger a sleeping comfort that was never possible
before: The lower bed is equipped with a pocket box spring mattress and can
be given a washable stretch bed cover. The upper bed has a foam mattress
and a contour supporting sprung slatted frame. When unused is is folded
upwards and secured, in sleeping position a retaining net protects the sleeper
from falling out.
The lower single-part standard bed is basic equipment for long-haul vehicle
with L or LH cab (with SC1 in F02 and F18: 1/3, 2/3 version). A gap has been
left in the rear wall in the upper body area to widen the lying area.
The standard bed has a single-part, high quality pocket box spring mattress. It
is removable and can easily be covered with a stretch bed cover.
The high sleeping comfort allows the driver and passenger to regenerate
within a short time. The improved support of the spinal column in the lower as
well as in the upper bed also ensures for long-term healthiness.
GT91_75_0003_C81

Shelves / accessories
Storage possibilities in the instrument panel area, in the roof area and rear wall
· Shelf with non-slip mat on the instrument panel, drawer beneath ashtray
· Cup holder for driver and passenger, stowage compartments left and right in the footwell
· Stowage compartment accessible from inside and outside
· Valuables compartment above the windshield (only with high roof), compartments over windshield and doors
· Megaspace total storage space approx. 475 l
· Two different kitchens as well as a TV- Video -DVD combination are offered as accessories.
GT68_00_0022_C71 GT68_00_0023_C71 GT68_00_0024_C71

Kitchens/entertainment components
GT68_00_0026_C80 GT68_00_0027_C71
The absolute highlight in the accessories program: For the new ACTROS with L The attractive TV-Video-DVD combination makes it possible. It is
and Megaspace cabs, we offer two Westfalia kitchens to quickly get rid of integrated in the passenger area in the storage module above the
large and small appetites: A compact and a comfort version. Both are fitted in windshield and gives the starting signal for rock and pop, cinema,
the upper part of the cab rear wall to make ample space for a microwave, evening television, video games etc. High-tech that can be seen and
coffee machine, 25 L refrigerator etc. An extremely useful feature that heard - and which is offered in individual components. That means:
contributes greatly to keeping the driver fit. What do they say: "There's no · a 10-inch monitor (with automatic adjustment for
place like home." contrast/brightness and automatic degaussing) including digital
satellite system (3000 program storage, timer, remote control).
Further accessory highlights: · DVD/CD player (NTSC/PAL system, front connection for
· CD changer external devices, e.g. game console).
· CB radio · Video player (PAL/SECAM, infrared remote control, repeat
· Stainless steel scuff plate function).
· Chrome step plates If one or the other entertainment components is not required the
· Velour floor mats installation space intended for it can be used as an additional
· Bulkhead box stowage compartment.

Door module removal and installation
Task 1
m In the video, you see the removal and fitting of the door module.
Note down the main points to be observed during removal and fitting!
W72.10-1021-11
The removal and fitting of the door module is described in WIS 1 Window pane
(AR72.10-W-0900A). 2 Window guide frame
3 Electrical connector
4 Guide rail
s
Electrical System Learn Targets 02.09.2004
After the working through this section you can...
· understand the power supply on the electric modules

· name the installation location of the power distributor
· assign the fuses in the power distributor to the corresponding modules
· name the installation location of the battery disconnect switch
· name the advantages of the vehicle networking
· understand the design of the KontAct vehicle networking
· describe the tasks of the base, front and rear modules
· name the electrical connection and the electrical fuses of the trailer socket
· read electric circuit diagrams
· operate the instrument cluster using the multifunction steering wheel
· understand the design of the modular switch panel
· explain the actuation of the exterior lights
· name the procedure when retrofitting a two-way radio, telephone and illumination

Electrical System Learn Targets 19
Electrics 02.09.2004
Overview of the power supply on a vehicle with integral rear end
BM
Alternator FM
(compact alternator RM
80 or 100 ampere)
Battery
(165 AH or
220 AH)
Starter
(reduction gear
starter as previously)
Power distributor
with jumpstart connection on the integral rear end
Note: Vehicle frame is without ground potential. When retrofitting, lay the ground line to the ground point. n
Electrics 20
Power Distributor 02.09.2004
The distance from the battery container to the starter is doubled on vehicles with an integral rear end. For this reason, the battery leads on these vehicles are
split in two and the cable cross-section is increased to 95 mm².
There is a disconnection point in the frame to allow easier assembly.
Vehicles with an integral rear end can be jump-started, in case of a breakdown, at the power distributor (arrows) because jump-starting directly to the batteries is
not possible on a coupled vehicle. There are two fuses in the power distributor. They protect the front module with 80 amperes and the rear module with 60
amperes. The base module is not protected.
GT54_10_0008_C71 GT54_10_0009_C71
Power distributor installation location Power distributor on integral rear end X128 Power distributor Terminal 30
F51 Front module fuse 80 A
F52 Rear module fuse 60 A

Power Distributor 21
Jumpstarting 02.09.2004
Task 1 m With a discharged battery, the engine can be started with jumper leads from the batteries of another
vehicle.
In the task, number the sequence in which you carry out the jump start procedure!
Remove jumper leads, first from the negative terminal then the positive terminal.
Power supplying vehicle: let the engine run with higher rpm.
Turn the key in the steering wheel lock all the way back.
Power receiving vehicle: Turn the key in the steering wheel lock to the drive setting. Start the engine
and let it run with idle speed. Switch on a large consumer, e.g. driving lights.
On vehicles with flame starting system: Before starting the engine, wait until the indicator lamp goes
out.
First connect the positive and then negative terminals of the batteries with the jumper leads.
Attention:
Observe the safety measures in the operating instructions!

Jumpstarting 22
GGVS Functions - Battery Disconnect Switch (BTS) 02.09.2004
The GGVS vehicle behaves the same as every other vehicle. Remote control as well as the locking system have the same functionality as vehicles without GGVS
equipment. The tachograph is supplied with voltage from the battery disconnect switch (K2). Only when at least one of the two EMERGENCY OFF switches is
pressed, is the on-board electrical system disconnected from the battery. An emergency stop switch is located in the cab, a further one is located on the right
behind the cab. When one of thew switches is operated, the BTS control unit informs the base module (BM) with a PWM signal that T. 15 is switched off for all
consumers, thus also stopping the engine. The battery disconnect switch (K2) is connected with the BM over the frame CAN bus, making it diagnosable.
K2 Battery disconnect switch

GGVS Functions - Battery Disconnect Switch (BTS) 23
Vehicle Networking Basics 02.09.2004
When the first electronic control units were used,

each was responsible for the acquisition of the
information it required from sensors.
Example: Coolant temperature
N00.19-2006-10
Today, a control unit captures the sensor data

and transmits this over a data line (CAN bus) to
the other control units.
Advantage:
· less sensors
· cabling expense is decreased.
N00.19-2007-10

Vehicle Networking Basics 24
CAN (Controller Area Network) data transmission lines
N54.18-2007-71 N54.18-2078-01 N54.18-2040-01
K-line Bus High-Speed CAN Bus Low-Speed CAN Bus

Is the data line with lowest data speed and, at the Here, data is transferred at very high speed on 2 The data speed on this line lies in the area between
same time, the line to the diagnostic system. twisted cables. the K-line and the high speed CAN. Two cables are
added for shielding, which are twisted with the data
No defined length limitation lines. These can also be used for the power supply
Max. cable length approx. 2m of the connected control units.
Max. cable length approx. 15m

Task 1 m Note down the advantages of data transmission over a CAN bus.
-
Data transmission with the engine CAN bus as example
The language for the exchange of data is binary code, i.e. only the logical values 1 and 0 occur. The
voltage level for the value 1 is approx. 2/3 of the battery voltage and for the value 0 approx. 1/3 of the
battery voltage. The voltages can have other values on different CAN bus connections.
W07.15-0011-01
So that distorted signals can be recognized, the voltage level of CAN h(igh) and CAN l(ow) are each
inverted. If the signal in one or both cables (CAN H, CAN L) is overlaid by a disturbance signal the faulty
area can be recognized by the control unit.
W07.15-0012-02

KontAct – Konzeption der Elektronikvernetzung im Actros (Actros Electronic Network Concept)
Main points of the network
· The network components are spread across the entire vehicle

· Only a few electronic circuits are located centrally in the electrical compartment
· The installed components are connected with data lines
· New CAN bus systems have been integrated
· Important tasks in the network have been reassigned to parts in the vehicle
· Functions of the old control units have been distributed to new components
· Control units have been completely integrated in other components and are no longer present in hardware form but still exist as software
· The depth of diagnosis has been extended
Note
Existing systems, such as the PSM, retarder or BS have been taken over almost completely unchanged from the previous ACTROS.

KontAct network diagram
n
AM Axle modulator SPA Lane assistant
AG Automatic gear selection SR Stability control
ANH Trailer electronics CAN interface SRS Supplemental restraint system
ART Autonomous intelligent cruise control TCO Tachograph
AUF Body electronics CAN interface TF Driver door module
BS Brake system TB Passenger door module
BTS GGVS battery disconnect switch TP Telematics platform
LWS Steering angle sensor RC Roll control
EAB Electronic trailer brake CAN interface WS Maintenance system
EDW Theft warning system WSK Torque converter clutch
FFB Radio remote control X13 Diagnosis test connector
FLA Flame starting system CDM Central data memory
FM Front module ZHE Auxiliary heater
FR Drive control ZL Auxiliary steering
GM Base module Z2 Terminal point 2
GS Transmission control
RM Rear module
HZR Heater control A Special versions CAN bus with 500 kBaud
INS Instrument cluster 1 Vehicle CAN bus with 500 kBaud
KB Clutch operation 2 Interior CAN bus with 125 kBaud
KDiag K-line diagnosis 3 Frame CAN bus with 250 kBaud
KNot K-line emergency running mode 4 Engine CAN bus with 125 kBaud
KOM Communication interface 5 Transmission CAN bus with 250 kBaud
KR Clutch control 6 Brake CAN bus with 500 kBaud
LWS Steering angle sensor 7 CAN interface trailer electronics with 125 kBaud
MSF Modular switch panel 8 CAN interface body electronics with 125 kBaud
EC Engine control 9 Telematics CAN bus with 250 kBaud
LC Level control 10 TCO CAN bus with 125 kBaud
PSM Parameterizable special module 11 CAN interface EAB with 125 kBaud
RD Tire pressure monitor
RS Retarder control

Virtual Control Units, Integrated Functions 02.09.2004
Virtual control units Control units have been combined in the scope of the new ACTROS KontAct networking. This means, they no longer have their
own housing and are now only present as software. The following electronic circuits have been integrated into the base module:
· WS maintenance system
· KOM communication computer
· ATA theft warning system
· RRC remote control receiver
· CDM central data memory
Note
Virtual control units are not present are components but can be selected and processed with the diagnosis device and
behave just like real control units.
Integrated functions Some of the previous control units have been integrated in other control units. These are not virtual control units.
They no longer appear in DAS and cannot be selected there. Their actuations, fault code and actual values appear under new
numbers in a different control unit. The following control units have been integrated:
· AG automatic gear selection is integrated in the FR
· KR clutch control is integrated in the FR
· NR level control is distributed in the front and rear module.
· WR roll control is distributed in the front and rear module.
Note
Integrated functions are distributed to other control units and can be found there in DAS. For this reason the function
entry has been taken over in DAS.

Virtual Control Units, Integrated Functions 30
To study the network in the ACTROS, you should look closely at the network diagram and work on the following tasks.
Note your findings
Task 1 m Assign the designations from the network diagram to the CAN BUS systems!
Frame CAN BUS

Vehicle CAN BUS
Transmission CAN BUS
Brake CAN BUS
Engine CAN BUS
Interior CAN BUS
Telematics CAN BUS
Tachograph CAN BUS
Task 2 m Which control units take part on the frame CAN BUS?
Task 3 m Which control units take part on the interior CAN BUS?

Virtual Control Units, Integrated Functions 31
Base Module (BM) 02.09.2004
The base module BM is located in the cab in the electrical compartment

and is accessible from outside and inside.
The BM is bolted to the frame of the FF connector.
The tasks of the BM can be divided into two groups:
· power distribution
· holding of relays and fuses
· information processing
· electronically protected load control
Input and output signals from the cab area are recorded and transmitted
here.
Base module with cab chassis connector

Base Module (BM) 32
W54.21-1269-06 W54.21-1270-06
Rear view, base module Front view base module
The base module is supplied with power from the screw bolts.
4 differently colored plugs are used in the base module. Each used color has its own mechanical coding. They are used in 6, 9, 12, 15, 18 and 21- pin versions.

Base Module (BM) 33
Base Module - Function 02.09.2004
Within the range of the network - KontAct - the base module takes over the following functions and tasks:
Important tasks, for which the base module is used:
ATA Theft warning system

KOM Provide telematics data
WS Maintenance system
RRC Radio remote control
CDM Central data memory
Exterior lights Actuation and monitoring
Interior lights Actuation and monitoring
Windshield and headlamp cleaning Actuation and monitoring
Power take-off Actuation and monitoring
Cab locking Monitoring
Trailer supply Power supply
Interface for accessory manufacturer plug X7 Plug X7
Function pins Stored parameterizable functions
Horn Actuation and monitoring
Turn signal indicator and hazard warning Actuation and monitoring
flasher

Base Module - Function 34
Relays and Fuses 02.09.2004
Please work on the questions about the base module. Use the operating instructions to do it!
Task 1 m 5 sockets are available in the base module relays.

Which tasks do the relays fulfill?
K1 -
K2 -
K3 -
K4 -
K5 -
Task 2 m Look at the melting fuse in the base module.

What do the specified fuses protect?
No. T. ... Designation No. T. ... Designation

F1 F15
F6 F21
F9 F23
F10 F25
F12 F31

Relays and Fuses 35
Additional fuses, relays and diodes can be
installed on additional rails on the base module
Additional fuses A1, A2

Additional relays (micro) A31
Additional relays (large) A32
Diodes D

Relays and Fuses 36
Central Data Memory (CDM) in the Base Module 02.09.2004
The base module has a central data memory (CDM), where all parameters from the electronic circuits fitted in the vehicle are stored. The
size of the CDM is 2048 kB.
The central data memory continuously keeps data ready for the control units. When needed, e.g. with an exchanged control unit, the
parameters are written to the new control unit from the central data memory.
The following data is stored in the CDM for each control unit:
· MB object number
· Hardware and software versions
· Diagnosis version
· Diagnostic data
· Date of the last diagnostic session
· Parameter data
· History data only for WS
Each time T. 15 is switched on, the date of the last parameter change in the control units is checked and compared with the CDM. When
parameter or control unit versions are changed, the CDM must be updated with the diagnosis device.
The data from the CDM is stored in a mirror memory (128 kB) in the instrument cluster for safety purposes. This makes it possible to also
exchange the base module and restore all data.
Note The data of the EC, FLA, MTCO and ART control units are no longer stored in the CDM.

Central Data Memory (CDM) in the Base Module 37
Trailer Socket 02.09.2004
The trailer socket is supplied by the base module.
Trailer recognition
The trailer recognition is implemented by a quiescent current over the output for the trailer and the output for the right and left trailer indicators. The trailer
recognition is carried out when switching on or switched on T. 15. The trailer is regarded as recognized when a load is recognized on one of these outputs.
Electronic protection of the outputs

The current that flows at the connection pin is measured. If this current exceeds the specified value for approx. 20 ms the connection is switched off (electronic
fuse).
The software recognizes shutdown of the driver and revokes the actuation of this driver. When required again, the driver is switched on again when T. 15 has
been switched off and on. The stop lamp of the trailer is protected by a melting fuse in the base module and has no electronic protection.
Turn signal indicator bulb failure recognition

On the first flash on and off, left and right after trailer recognition "trailer present", one current measurement takes place for each side. It can be detected
whether one or two bulbs is present on the trailer when the current of a bulb is compared with a stored value.
The power consumption of both sides are compared with each other. If the measured values were within a plausible range their values are stored. The measured
current is compared to the stored value on the next indicating process. A difference is evaluated as a bulb failure and is shown as a fault in the display where the
base module no longer actuates the indicator control of the trailer in INS and increases the indicator pulse to the double frequency.

Trailer Socket 38
Current load on the 15 pin trailer socket:
Designation Pin Max. current Designed for

Left indicator relay external 1 2A 2 x 21 W; 150 mA
Right indicator relay external 2 2A 2 x 21 W; 150 mA
Rear fog lamp, relay external 3 2A 2 x 21 W; 150 mA
T. 31 4 10 A
Trailer socket, left standing lamp T. 58 L 5 4A
Left taillamp 2x 10 W
Left clearance lamp 2x 10 W
Rear left license plate light 2x 10 W
Side-marker lamps left 7x 3 W
External relay 150 mA
Trailer socket, right standing lamp T. 58 R 6 4A
Taillamp right 2x 10 W
Right clearance lamp 2x 10 W
Rear right license plate light 2x 10 W
Side-marker lamps right 7x 3 W
External relay 150 mA
T. 54 stop lamp 7 7.5 A Fuse F23 15 A
Relay plug position K1
Backup lamp, external relay 8 4A 4 x 21 W; 150 mA
T. 30 9 10 A Fuse F5 20 A
Spare 1.5 mm2 10 FF 5.1 18/5
Spare 1.5 mm2 11 FF 5.1 18/6
Spare 1.5 mm2 12 FF 5.1 18/7
T. 31 13 10 A
Trailer CAN bus, CAN high 14 to PSM
Trailer CAN bus CAN low 15 to PSM

Trailer Socket 39
Electric Circuit Diagrams 02.09.2004
How do I actually read a circuit diagram?
Let's just build such a circuit diagram together, then it will be easier.
In our circuit diagrams, there is, similar to a street

map, coordinate system.
a) The letters mark the rows.

b) The numbers sequentially number the
columns.
c) The coordinate specification always begins
with the number.
Task 1
m Determine the coordinates for the "parts" in

the illustration!
Coordinate 1
-
Coordinate 2
-
N00.19-2011-05

Electric Circuit Diagrams 40
Task 2 m In the circuit diagrams, find the diagram for the working lamp. Complete the table! Use the "Usage of
electric circuit diagrams" to do this!
On semitrailer/tractors On flat-bed vehicles

Working lamp designation - -
Circuit diagram designation and no. - -
Coordinates on the circuit diagram - -
Connected to plug and pin - -
Cable cross-section in mm² - -
Cable colors - -
Designation of further connectors and pin -
designation between control unit and working
lamp

Electric Circuit Diagrams 41
Front Module (FM) and Rear Module (RM) 02.09.2004
The front module (A64) FM is located in the vehicle on the passenger side under the cab. All input and
output signals from the front area of the vehicle are recorded and transmitted here. This means, all
sensors and actuators in the front area are connected to the front module.
W54.21-1217-11
The rear module (A65) RM is located behind the rear axle on the right of the vehicle chassis. Here all
tasks are performed that are to be controlled and monitored in the rear area of the vehicle. This means, all
sensors and actuators located in the rear area are connected to the rear module.
W54.21-1218-11

Front Module (FM) and Rear Module (RM) 42
The front and rear modules have the same housing. They
differ only in their internal life.
All components are connected by the plugs X1 -- X6.

The modules have no melting fuses. All outputs are
electronically protected by an overcurrent circuit breaker. The
inputs are also short-cicuit protected.
The power supply is connected to T. 30 and T. 31 on plug X7.

The front module is directly supplied from the power
distributor and is protected there with an 80 A melting fuse,
the rear module with 60 A.
W54.21-1188-14
The connectors are easily accessible under a cover
· The plug housings are coded and protected against swapping. The plug housings are secured against slipping.
· Each individual wire is protected against water and dirt in the plug with a single-wire seal.

Front Module (FM) and Rear Module (RM) 43
Front and Rear Modules - Functions 02.09.2004
Within the network - KontAct - the front and rear modules take over the following functions and tasks.
Important functions integrated in the front module:
· Illumination: Actuation and monitoring of the bulbs in the front area of the vehicle
· Sensors: Read in and monitoring of all sensors in the front area of the vehicle
· Actuators: Control and monitoring of all actuators in the vehicle front
· Locks: Actuation and monitoring of all solenoid valves for transverse and interaxle differential lock
Important functions integrated in the rear module:
· Illumination: Actuation and monitoring of the bulbs in the rear area of the vehicle
· Sensors: Read in and monitoring of all sensors in the rear area of the vehicle
· Actuators: Control and monitoring of all actuators in the rear of the vehicle
· Level and roll control: Actuation and monitoring of all solenoid valves
Note: The outputs of the modules are electronically protected.

Front and Rear Modules - Functions 44
Base, Front and Rear Modules 02.09.2004
Sensors, switches and actuators are connected to the modules and networked each other over CAN bus systems.
Task 1 m Mark the module in the table to which the listed parts are connected!
With difficult parts, use circuit diagram!
Component FM BM RM Component FM BM RM
FA position sensor for level control Horn

RA position sensor for level control Air horn solenoid valve
Condensation sensor FA differential lock solenoid valve
Brake wear warning sensors FA differential lock indicator switch
Parking brake switch RA differential lock solenoid valve
Outside temperature sensor RA differential lock indicator switch
Rear axle temperature Heating air drier
Wiper motor for windshield Cab locking
Auxiliary high beam Steering oil level indicator switch
Taillamps Fuel tank sensor
Side-marker lamps Interior lights

Base, Front and Rear Modules 45
Instrument Cluster 02.09.2004
W54.30-1224-05
· 5 own control buttons

· 8 places for retrofitted indicator lamps
· No main function in the network
· Mirror memory (128 kB) for central data memory (CDM)
· Acoustic function replaces warning buzzer
· Timer for the auxiliary heater control
· Integrated alarm
The are 4 different versions that differ, for one thing, in the speedometer display up to 125 km/h or up to 140 km/h. There are also two distinguishing features
in the tachometer display, a variable or fixed tachometer range.

Instrument Cluster 46
Aufgabe 1 m The instrument cluster is operated with 5 function buttons.
Find out the meaning of the pushbuttons using the operating instructions!

Indicator lamps in the instrument cluster
Turn signal High beam Permanent Parking brake STOP Cab locking ASR / SR Permanent Turn signal
lamp tractor/ brake active brake on lamp tractor /
trailer automatic trailer
left right
Retrofit Dumper Flame starting Lane assistant Torque Auxiliary steering Hill holder Frequent-stop Retrofit spaces
spaces control system (FLA) (SPA) converter (ZL) brake
clutch (WSK)

Sound Module - Instrument Cluster 2002 02.09.2004
The sound module integrated in the instrument cluster generates various, content-
related warning and feedback sounds and controls their output. The triggering of a Sound module
sound takes place internally through the instrument cluster itself as well as through
other control units that communicate with the instrument cluster over the CAN bus.
Warning sounds
· Warning buzzer
· Lights-on buzzer
· Warning sounds for ART
Feedback sounds
· Gearshift lever noises
· Indicator noises
· Key acknowledgement
· Signal of the hands-free system
B28 Middle loudspeaker in roof

X124.1 Connector
The first coil of the double-coil loudspeaker is used by the radio.

The instrument cluster actuates the second coil of the middle loudspeaker for the
acoustic playing of the generated sound . Only one noise can be generated (set by
priority) at any one time.
GT54_30_0017_C03

Sound Module - Instrument Cluster 2002 49
Driver Information System 02.09.2004
The FIS displays information about the operating condition of the

vehicle and warnings to the driver.
Furthermore, diagnosis functions and settings for the display are
available. The graphical display is located in the middle of the INS and
is operated with the steering wheel buttons.
Default display
The default display of the FIS can be selected by the driver.
· a black screen
· a digital speedometer
· the current date
· the temperature of the interior heating
With the exception of the gear indicator, all displays can be

switched on and off.
Event display
When a fault occurs, an event message is displayed in the middle of
the screen. The background of the event message will be yellow or red
depending on its importance.
1 Status display (red)

2 Reservoir pressure brake
system
3 Fault location
4 Function limitation
5 Action instruction

Driver Information System 50
The multifunction display is divided into fixed areas. 01 Actros-info 01
1 Navigation bar
2 Selected default display
3 Level control
4 Gear indicator with splitter setting and display of the preselected gear
5 Reminder field for fault display; only serious faults in the BS and TCO will be
displayed with the system symbol
6 Display window for locks and power take-off
7 Display window for cruise control or ART functions
Reduction of "display stress" through logical filtering of event messages.

The driver is now only shown events that are relevant for him or fulfill one of the following criteria:
· legally required display
· safety-relevant display
· fault can lead to consequential damage

Driver Information System 51
Multifunction Steering Wheel 02.09.2004
The multifunction steering wheel is a new product and a new feature in the commercial vehicle area.
General
The multifunction steering wheel allows the driver to operate and read out
various systems (depending on model and equipment). All available functions
are combined in FIS (driver information system):
The following menus, among others, are available to invoke the functions:
· "Control Info", to display the coolant temperature or of the engine oil level,
for example.
· "Audio", to adjust the volume level or to operate the CD or cassette player
· "Maintenance", to display the calculated maintenance dates
· "Phone"
· "Destination", to the operate the navigation system
· "Trip computer"
· "Settings", to set the time, for example
· "New messages", on vehicles with FleetBoard
1 Function buttons W46.10-1009-81

Multifunction Steering Wheel 52
Function buttons
Task 1 m Work out the meaning of the function buttons on the multifunction steering wheel!
Use the operating instructions to do this.

Navigation in the driver information system (FIS) 01 Actros-info 01
To page through the menus, use the buttons on the multifunction steering wheel
to page forwards or backwards.
NOTE:
The main menus are displayed according to the installed equipment.
You can scroll up or down in the menus using the multifunction 01 Actros-info 01
steering wheel buttons.
NOTE:
The submenus are displayed according to the installed equipment. 01 Actros-info 02
The menu items are selected or the volume level controlled with the multifunction
steering wheel buttons or .

The following menus can be selected with the function buttons:
n
Star Diagnosis (DAS) 02.09.2004
A high-performance diagnostic system has been introduced with STAR DIAGNOSIS, which further optimizes the advantages of DaimlerChrysler AG products in
the service area. For this, STAR DIAGNOSIS uses the latest data processing technologies and orients itself to future developments in this area. Workshop
processes can be accelerated and error rates reduced with STAR DIAGNOSIS, which improves the work quality. The system is designed with orientation to the
future. Nowadays, the STAR DIAGNOSIS is available in three system versions:
STAR DIAGNOSIS Station MT STAR DIAGNOSIS Compact STAR DIAGNOSIS basic
GT00_00_0003_C11 GT_00_00_0002_C11 GT_00_00_0085_C01

Star Diagnosis (DAS) 56
STAR DIAGNOSIS Station MT is based on the known applications, which have been further developed in many areas. The hardware components consist of a
stationary rollboy, which contains the diagnosis device with standard laptop in a plastic shell and a laser printer. The diagnosis device can easily be removed from
the rollboy unit for mobile use. MT stands for the integrated engine test and measuring equipment - functionality.
STAR DIAGNOSIS Compact differs mainly from the STAR DIAGNOSIS MT station in the hardware. Through this more advanced concept, the mobile handling
could be improved once again and thus extends the STAR DIAGNOSIS product range. This unit is also contains a standard laptop.
STAR DIAGNOSIS Compact can optionally be ordered or retrofitted with the MT engine test functionality, from Hermann Electronic GmbH. This provides a variety
of different measurement and test possibilities on the vehicle and is designated with STAR DIAGNOSIS Compact MT.
HMS 990 (Hermann measuring equipment

system)
P00-.00-2706-01
STAR DIAGNOSIS basic is a small powerful computer, which can be used particularly well everywhere where mobility and dynamics ensure an increase in
customer satisfaction through idle and waiting times, e.g. customer reception and with 24h service. To ensure easy handling in the workshop area, operation of
the Star Diagnosis Basic has been implemented from a touchscreen.

Software
Since the introduction of STAR DIAGNOSIS, the software has been significant further developed. Windows NT 4.0 now serves as the platform for the various
application programs. The Diagnosis Assistance System (DAS) supports fault finding on the vehicle using decision trees and important notes. HHT-WIN covers all
functions of the old HHTs. The interfaces to the Workshop Information System (WIS) are integrated in STAR DIAGNOSIS.The Hermann measuring equipment
system (HMS 990), with its various measuring and test possibilities meaningfully round-off the entire diagnostic system.
Support responsibility
To ensure an optimum follow-up of all service outlets, the introduction of STAR DIAGNOSIS Compact takes place through a main contractor, who operates
worldwide. This function has been taken over by IBM: Hardware, pre-installation, national version certification (DIN, ISO etc.), service, system maintenance,
hotline support. The distribution of data and updates will also take place in future through DaimlerChrysler AG channels, which are already in use today for the
products WIS, EPC, HHT and for the service literature.
Advantages of STAR DIAGNOSIS
STAR DIAGNOSIS
· allows guided tests, shows installation locations in pictures (photos) and, additionally, provides an illustration of circuit diagram excerpts and technical
drawings on one and the same device. This avoids unnecessary search times for information.
· provides the full functionality of today's HHT on a laptop as its own application (HHT-WIN) with "quick test", "fault memory read/delete", "carry out
actuations and parameterization", "display actual values". The user interface corresponds to today's HHT.
· ensures a new diagnosis quality through a higher level of detail, a lower false diagnosis rate and a reduction of removal of non-defective parts.
· provides improved power for the user. The worldwide introduction took place in 1998. The training takes place with a modular concept. Furthermore, there is
the worldwide STAR DIAGNOSIS hotline support in six languages (German, English, French, Spanish, Italian and Japanese) for all questions and incidents.
· increases customer satisfaction because idle times are further shortened, unnecessary repairs are avoided, the rate of repeat repairs are significantly
lowered and the maintenance and service costs decreased.
· Through continuous further development of all components, will also meet future requirements of the service outlets.

DAS Simulation
The simulation is started with a <click> on the corresponding menu item, which
means the separate starting of DAS is no longer necessary.
The simulation provides the user with the possibility of having all control units,
the corresponding fault codes, actual values and diagnosis scope displayed for
the correspondingly selected vehicle.
If the customer also is shown a fault code on the on-board diagnosis the
technician can make a faster assessment of the complaint complexity, even
without being on the spot.
Furthermore, the simulation is used for training purposes.
GT00_00_0021_C06
n
Practical <> Instrument Cluster and On-board Diagnosis 02.09.2004
Practical work in 2 groups on the vehicle
Driver information system On-board diagnosis

Instrument cluster DAS Simulation
Target: Target:
Describe the control of the FIS in instrument cluster. Correctly assign and interpret the displays of the on-
Name innovations of the FIS. board diagnosis.
Task: Task:
Read out realistic information in FIS. Decipher the specified fault code from the DAS
Presentation of results by a group simulation and determine the source of the fault.
Presentation of results by a group
Time: Time:
30 minutes 30 minutes

Practical <> Instrument Cluster and On-board Diagnosis 60
Station 1 <> Driver information system, instrument cluster
Please work on the practical tasks for the operation of the FIS in the instrument cluster of the ACTROS. Use of the operating instructions for this!
Make notes of your procedure!
Task 1 m The diagnosis menu must be enabled.

How can the diagnosis menu in FIS be activated using the steering wheel buttons?
Task 2 m How can an event code be read out in FIS, after the diagnosis menu has been activated?

Task 3 m Read out the brake wear off and enter the values!
(MW = measurement value)
Front module Rear module

Axle A1 left % MW2 Axle A3 left % MW2
Axle A1 right % MW3 Axle A3 right % MW3
Axle A2 left % MW4 Axle A4 left % MW4
Axle A2 right % MW5 Axle A4 right % MW5
Note:
The parking brake must be released, otherwise implausible values will be displayed!
Task 4 m Read out the engine oil level. How do you proceed?
Task 5 m How are maintenance dates acknowledged in WS?

Task 6 a) In which menu can the alarm be set?
b) How can the driver have himself woken?
Task 7 m Adjust the time by 1 hour. Note down the special features to be observed with regard to the
tachograph.
Task 8 m Read out the reservoir pressure in the multifunction display off and enter the values!
Circuit 1 - bar
Circuit 2 - bar
Task 9 m The windshield wiper-interval can set steplessly. Using the operating instructions, find out the min.
and max. time to which the intervals can be set.
Min.: -
Max.: -

Station 2 <> Driver information system, instrument cluster
The headlamp can be swung out to change the bulb.
Task 1 m Swing the headlamp out. Look at the mounting and adjustment possibilities of the headlamp. Note
down the task of the illustrated bolts.
Bolt no. 1 -
Bolt no. 2 -
Bolt no. 3 -

Events are shown to the driver in the driver information system (FIS). Depending on type of event, the status display lights yellow or red.
Event message with action instruction Event message with symbol

Example: Example:
5 Action instruction 2 Coolant temperature symbol

6 Reminder field 3 Yellow status display
7 Reminder field
Task 2 m What are the instructions in the operating instructions when faults with yellow and red status displays
are to be remedied?
Yellow status display: -
Red status display: -

Further information about the event can be found in the diagnosis menu of FIS
Event display in FIS example:
1 Event number 3 Event priority 5 Event text

2 Current event 4 Event code 6 Action instruction
The event code can decoded using the DAS simulation. Notes on the symbols used are stored on the F6 button.
Task 3 m Decode the following event code with the DAS simulation. When decoding, the priority is not reflected.
Event code Event text Brief information, possible causes (F3 button)
BS 24041 - -
HM 1241E - -
MSF 13D15 - -

Task 4 m Using the DAS simulation, find out the following information:
a) What can you parameterize in the FM when you retrofit side-marker lamps?
b) Enter the CDM system and get yourself an overview using the DAS simulation.
Which possibilities are available in the CDM in the "special functions" menu?

Modular Switch Panel (MSF) 02.09.2004
The new design of the switch panel improves the ergonomics for
the driver. The switches with important functions, that must be
used while driving, have been placed together in the easily
reachable modules.
Further switch panels are located in the headliner above the driver
area and in the side wall.
Advantages:
· reduced number of cables and connectors
· reduced cable sets and weight
· optimized installation space and routing radiuses
· improved individual adjustment
· simplified retrofitting
GT54_25_0011_C81

Modular Switch Panel (MSF) 69
Modular Switch Panel Networking
W54.25-1022-79
1 ASIC data bus A69 Dash support switch module 9 A81 Dash support switch module 8
10 Driver dash support area A70 Rear wall switch module 13 A82 Locking switch module 6
11 Middle dash support area A71 Roof switch module 11 A83 Roof switch module 10
12 Left dash support area A76 Dash support switch module 2 A84 Rear wall switch module 12
13 Roof area A77 Dash support switch module 1 CAN 2 Interior CAN
14 Rear wall area A78 Dash support switch module 3 S24 Light switch
A7 Base module A79 Dash support switch module 5 S25 Combination switch
A68 Master switch module 4 A80 Dash support switch module 7 S26 Headlamp range adjustment

Modular Switch Panel (MSF) 70
Modular Switch Panel - Components 02.09.2004
Master module
Function
* Read in switch signals from all connected parts
* Read in CAN messages from all signal switches
* Spaces for 2 signal switches
* Integrated hazard flasher switch
* Transmission of the switch signals to the base module
* Actuate switch illumination
* Switch monitoring
GT54_25_0003_C80
Slave module
Function
* Read in CAN messages from all signal switches
* Spaces for max. 4 signal or power switches
* Transmission of the switch signals to the master module
* Actuate switch illumination
GT54_25_0004_C80

Modular Switch Panel - Components 71
Modular Switch Panel - NEW Switches 02.09.2004
ASIC switches (signal switches), when pressed or requested, transmit a data packet over the ASIC data bus to the modular switch
panel and thus pass on the switch requirement to the master switch panel. Each switch transmits its own data packet and has a
fixed assigned function and thus its own identity and also its own part number.
Function
· transmit its own switch identification over the ASIC data bus
· transmit switch information on the ASIC data bus
· pickup information over the ASIC data bus
· actuate switch lighting
· actuate the indicator lamps in the switches
Special feature
Individual functions, e.g. the interior lights, can be switched on from the driver area as well as from the bed.
To avoid problems, no switch with the same part number may be installed more than once in the MSF!
GT54_25_0013_C71
Power switches
Power switches have, in addition to their connection pins to the ASIC data bus, power pins to perform their
function directly from the switch.
Function
· switch the consumer directly from conventional power pins
· pickup information over the ASIC data bus
· actuate switch lighting
· actuate the indicator lamps in the switches
Power pins
· switch the relevant function directly, max. load 20 A
GT54_25_0012_C71

Modular Switch Panel - NEW Switches 72
Steering column lever
Functions
· turn signal left/right
· low/high beam
· headlamp flasher
· wiper 3-step, intermittent wiper, screen wipe wash, single wipe
· horn
· switch position is reported to the MSF
The steering column lever is connected to the master switch panel of the MSF. Switch signals
in the steering column lever are read in and monitored there and sent to the base module over
the CAN.
The steering column lever may not be loaded with any further consumers!
Exterior lamp switch
Functions
· standing lamp
· low beam
· fog lamps
· rear fog lamp
The position of the exterior lamp switch is read in to the master switch panel from internal
microswitches and the current switch position is recognized.
The switch is monitored by the modular switch panel, interpreted and the switch position
transmitted to the base module.
The exterior lamp switch may not be loaded with any further consumers!

Modular Switch Panel - NEW Switches 73
Modular Switch Panel and Illumination 02.09.2004
Failure of the modular switch panel can lead to limited functionality. Answer the following tasks to become familiar with the modular switch panel.
Task 1 m What effect does failure of the modular switch panel power supply have on the function of the tilting/
sliding roof?
a The switch is a signal switch. When the power supply fails, the ASIC subbus system also fails and the
function is not carried out.
b The switch is a power switch that does not get its power supply from the master module. The
functionality is not affected.
Task 2 m How can the tilting/ sliding roof be closed in an emergency?

Use the operating instructions!
Task 3 m What effect does an interruption of the modular switch panel power supply have on the tail lift switch
on/off function?
a The switch is a signal switch. When the power supply fails, the ASIC subbus system also fails and the
function is not carried out.
b The switch is a power switch that does not get its power supply from the master module. The
functionality is not affected.

Modular Switch Panel and Illumination 74
Retrofitting of NEW Power and Signal Switches 02.09.2004
Power switches
Three power switches are planned for retrofitting: Retrofit Retrofit

· Retrofit 1 power switch power switch
· Retrofit 2 general axles
· Retrofit axles
The switches offer the possibility of switching any loads on and off directly with the switch.
For this, it is required that the load to be switched is directly wired to the switch.
Interior circuit diagram:
· lock
· double rocker
· 2 x closers
· power switch
· 2 x FA (directly) function indicator
· 2 x SB (switch illumination)

Retrofitting of NEW Power and Signal Switches 75
Signal switches
The signal switches for retrofitting are: Retrofit

· Retrofit 1 function pin and signal switch
· Retrofit 2 function pins
The switches are simply plugged in the modular switch panel and their function is guaranteed. The signals of these
switches are evaluated in the base module (BM) and the function pins actuated. Extensive parameterization possibilities
are specified in the BM.
The accessory manufacturer can place the symbols for the retrofit switches himself.
There are special switches for subsequent fitting of units, which can also be offered from the factory as special equipment.
Necessary work when retrofitting switches in MSF:

1) Push the plug in
2) Signal switches. switch is automatically initialized, the signal is immediately available.
Power switches. Wire switch accordingly.
3) Adjust parameterization: A list of predetermined equipment is stored in the master module. The new switches should be entered here as "fitted". When a
deviation is found to the actually found switch, the control unit stores a fault ("too many/ missing switches"). The monitoring for all retrofit and reserve
switches is currently switched off. This means that the switches can be inserted without generating a fault.

Retrofitting of NEW Power and Signal Switches 76
Xenon Headlamps - Design and Function NEW 02.09.2004
A new generation of headlamps is used in the ACTROS model refinement. With these clear-glass headlamps, the distribution of light is no longer controlled by a
diffusing lens but by the shape of the reflector.
ACTROS from 2003
5 4
2
3
2
3
4
GT82_10_0011_C71
1 low beam The lamp unit of the Xenon headlamps consists of:
2 high beam
3 standing lamp 1 Gas discharge headlamp
4 fog lamps 2 Ignition module / control unit
5 turn signal lamp 3 Electrical connection (to front module)
Note
Due to the high light output of the high beam, no additional headlamps may
be installed on the ACTROS!

Xenon Headlamps - Design and Function NEW 77
Function
When the low beam is switched on, the control unit activates the ignition
module within a few milliseconds with the control voltage. An electric arc is
formed between the electrodes with a high voltage pulse, approx. 20 kV, and
the Xenon lamp is ignited.
If an electric arc of sufficient stability is recognized the control electronics

switches to limited power operation. The electrical power is stabilized at 35
W. A voltage converter generates the voltage of approx. 85 V required for the
safe function of the Xenon lamp.
Xenon headlamp control unit GT82_10_0013_C80
Headlamp cleaning system

The light beams are refracted by dirt particles on the surface of the headlamp
lens and dazzle the oncoming traffic. With Xenon headlamps, this dazzle effect
is very high due to the high light intensity.
For this reason, headlamp cleaning systems are legally required for headlamp
units with gas discharge headlamps.
The nozzles are installed in a telescoping section above the lamp unit. The
headlamp cleaning system is activated by a separate switch.

Xenon Headlamps - Design and Function NEW 78
Gas Discharge Headlamps - Design and Function 02.09.2004
Function
The burn chamber of the Xenon lamp is filled with Xenon and a mixture of metal-halogen salts. This
mixture is ignited by a high voltage. The color of the light has a daylight-similar character.
The technical features of Xenon lamps gives them a long start-up time. After switching on, 50 % of the
brightness is reached within 1 up to 2 seconds 50 % and full brightness is reached after approx. 30
seconds.
Xenon gas discharge headlamp

GT82_10_0015_C73
The light output in comparison:
Halogen low beam (H7) Xenon light

Gas Discharge Headlamps - Design and Function 79
a Risk of death through high voltage on Xenon headlamps
Safety regulations for the handling of Xenon headlamps

WIS: AS82.10-Z-0001-01A
Risk of death
Xenon headlamp operate in a dangerous power range. Due to the high voltage, contact with electrically conducting parts can
be life threatening!
Electric shocks can lead to ventricle fibrillation or cardiac arrest. The consequences of an electric shock may first appear after
a few minutes, so always contact a physician.
Safety instructions/precautions
* Persons who have electronic implants (e.g. pace-makers) are not to carry out work on the Xenon headlamps.
* The lighting must be switched off before working with Xenon headlamp (e.g. exchanging parts, connection of testing devices,
etc.).
* When the Xenon headlamps are on never touch parts that are conducting electricity.
* Wear safety shoes (with rubber soles).

Gas Discharge Headlamps - Design and Function 80
Practical <> Modular Switch Panel and Illumination 02.09.2004
Practical work in 3 groups

Modular switch panel
Illumination on the vehicle
Target: 1
Carry out realistic operations on the modular switch panel and
illumination.
Task:
Work through the following task sheets at the 3 stations. Note your
findings.
Presentation of results by a group.
Time:
3 2
25 minutes each
Illumination
Illumination Theory Safety Concept
P00.00-1185-11

Practical <> Modular Switch Panel and Illumination 81
Station 1 <> Modular switch panel - illumination on the vehicle
Please work on the tasks for illumination on the ACTROS to deepen the topic of illumination and networking.
Use the workshop literature for the questions.
Task 1 m How does the vehicle lighting behave when a fault is present in the MSF system?
* Pull off the plug for the light switch from the master module.
* Switch the ignition on.
Then remedy the fault on the vehicle!
-
Task 2 m How does the vehicle lighting behave when a fault is present in the MSF system?
* Pull off the plug for the light switch from the base module.
* Switch the ignition on.
-
Task 3 m Remove both S45 buttons (rear wall and roof above) for the interior lights and note down the part
numbers. Replace the buttons in the correct position!
Side wall button -
Top bulkhead button -

Station 2 <> Safety concept - illumination on the vehicle
Task 1 m How does the illumination behave when the power supply of the FM or RM is disrupted?
* Disconnect the battery
* Remove the fuse in the power distributor for the FM
* Connect the battery again
* Switch through the illumination one after the other.
Vehicle with standing lamp -
Vehicle with low beam -
Vehicle with low beam and hazard warning flasher -
Task 2 m The WIS document OV8210-W-3013MP describes this emergency lighting actuation. Please find
answers for the following questions!
a) From which line is the front module supplied with voltage?
-
b) How high is the maximum current that flows there?
Task 3 m Connect the STAR Diagnosis to the vehicle. Select the front module. Carry out the actuation of the
illumination. Note down the lamps to be actuated.

Station 3 <> Illumination - Theory
Task 1 m Please work on the questions about the lighting on ACTROS MPII.
Use the workshop literature and circuit diagrams for this!
Enter the modules, responsible for the actuation of the named lamps, in the table!
Low beam
TMB
Lamps in entrance
Entrance lamp in the door

BM FM
Rear fog lamp
Clearance lamps front

RM
Side-marker lamps
MSF
Fog lamp
Trailer light
Turn signal indicator for trailer INS

Cab interior lights
TMF

Task 2 m Assign the parts and data bus systems in correct sequence, which are necessary for the actuation of
the standing lamps.
GF82.10-W-3000MP From BM over frame CAN bus to FM to RM.
Light switch to MSF master module.
From MSF over interior CAN bus to BM.
From BM to the trailer socket.
Task 3 a) Look at further lighting actuations.

What is the signal path for the actuation of the stop lamp with BS?
GF82.10-W-3010MP
GF82.10-W-3011MP -
b) What is the signal path for the actuation of the backup lamp with GS?

Power Tapping 02.09.2004
Power Tapping on the Frame

Additional distributors have been provided for power tapping in the frame. These are simply plugged on to the existing power distributors. Plus and ground is
tapped in these distributors. The positive lead is protected by a melting fuse. Depending on requirements, additional tappings (1-3) can be made.
1 2 3
GT54_10_0022_C75
Task 1 m Find out how large the max. current (A) may be, which can be additionally tapped from the extension
of the power distributor. You can find notes in the equipment mounting directive.
Note: The equipment mounting directive can be called up in the Internet under http://mbas.mercedes-benz.de/arl/.

Power Tapping 86
Plug X7 on the Base Module 02.09.2004
The plug X7 on the base module is intended for tapping the most important signals for connecting an accessory.
W54.21-1288-79
Legend:
A7 Base module (243) Backup lamp (795) Plug X7 electrical interface to accessory
X7 pin assignment
Pin 1 T. 58 standing lamp/2A Pin 4 Backup lamp/2A Pin 7 T. 31
Pin 2 T. 30/10A Pin 5 T. W/10mA Pin 8 v-signal/10mA (8 pulses/m)
Pin 3 T. 54 stop lamp Pin 6 T. D+ Pin 9 T.15/10A

Plug X7 on the Base Module 87
Retrofitting Two-Way Radios 02.09.2004
A radio pre-installation is available for the Actros (in Germany as The antenna concept on the roof currently looks like the illustration.
standard).
2
6
1 5
2 1
3
4
GT82_70_0014_C71 GT82_62_0003_C81
1 Two-way radio installation location 1 CB radio antenna
2 Loudspeaker installation location 2 Radio antenna
3 GPS antenna/navigation unit
4 GPS antenna/FleetBoard
5 GSM antenna/FleetBoard
6 GSM antenna/phone

Retrofitting Two-Way Radios 88
Retrofitting Phones 02.09.2004
Preinstallation phone, fax (SA Code EV5 Standard for Germany)
With this preinstallation any phone can be fitted. The required voltages are provided by plug
X63 and is shown in the circuit diagrams phone PE82.70-W-2000D and PE82.85-W-2005A.
An antenna with dual-band transmitter is already installed on the roof.
The connectors are located in the electronic compartment cover.
GT82_70_0016_C71
Hands-free system for phone (SE code EV7)
With this preinstallation portable CTELs can be simply connected to the vehicle. For this,
there is an accessory cradle (B6 part number and Mercedes star), which can be connected
with the preinstallation. The portable CTEL can be placed in this cradle. Portable CTEL
cradles are available for Nokia and Siemens phones.
To use all the functions, it is necessary to use a cradle from the Mercedes-Benz accessories
for the ACTROS MP II. Other cradles are not fully functional!
GT82_70_0015_C71
Task 1 m Look at the installation locations of the two-way radio and phone preinstallations on the vehicle.

Retrofitting Phones 89
Retrofitting Work Lamps 02.09.2004
Task 1 m A work lamp (with original switch) is to be retrofitted to a customer's vehicle. With the extensive
networking in the Actros, the procedure is easy.
The function is described in the WIS document OV82.10-W-3018MP.
Complete the block diagram and mark the involved modules!

Retrofitting Work Lamps 90
Retrofitting sidelights 02.09.2004
You want to mount additional sidelights (E47) on the cab roof.
Task 1 m Using the electric circuit diagrams, determine the corresponding circuit diagram, control unit, plugs
and pins to which the sidelights are to be connected. Note these down.
Circuit diagram: -
Control unit: -
Plugs: -
Pin: -
Task 2 m a) Connect the lamps to the control unit, plugs and pins that you determined.
m b) In the control unit, parameterize the corresponding parameter so that the sidelights light up in
conjunction with the standing lamps. Note the parameters.
Parameter no.: -

Retrofitting sidelights 91
Learn Targets <> Drive Train 02.09.2004
M
After this chapter you can . . .
Drive train: Steering:
q name the technical features of the BR 500 engines. q describe the design and function of the LS6/8 power steering.
q name the rpm, which provides the largest torque. q describe the ventilation of the steering.
q roughly describe a performance graph. q describe and adjust the steering play.
q describe the high torque rise using the diagram. q carry out the limiter setting.
q name the 4 eco-point versions of the engines. q describe faults on the steering.
q describe the design of the oil and fuel circuit.
q explain the fitting and removal of the unit pump and injection nozzles.
q describe the design of the various fan types.
q describe / name the valve settings.
q explain the operation concept of the drive systems.
q name the differences of the clutch.
q explain the design, function and differences of the shift systems.
q understand the changes on the sensor unit.
q activate the backup drive mode.
q explain the innovations on the clutch actuator.
q name the advantages of the nickel-plated hub of the single-plate clutch.
q describe the task of the clutch sensor.
q describe the task of the clutch booster.

Learn Targets <> Drive Train 92
Engine: Model Series 500 02.09.2004
The engine model series 500 is offered as V6 and V8

cylinder with 2 liter swept volume per cylinder.
500 Series
The sales designation is similar to the model series 400:
6-cylinder engine: OM 501 LA

6-cylinder V engine 8-cylinder V engine
8-cylinder engine: OM 502 LA
501 LA 502 LA
.
VS = 12 l VS = 16 l
OM 501 LA
Turbocharger
Charge air cooler
1 = 6-cyl. V engine
2 = 8-cyl. V engine
500 series
Oil engine

Engine: Model Series 500 93
OM 457 LA engine in cross-section
N01.00-2010-50 N01.00-2009-50

Engine: Model Series 500 94
BR 500 Technical Features 02.09.2004
ð Outstanding power and torque characteristics over the entire rpm ð Optimized engine cooling with ring fan
range ð Viscous fan clutch, electromagnetic fan clutch and high-speed fan
ð Low fuel consumption drive on the highest powered engines
ð High pressure direct injection with unit pump, pump-line-nozzle system, ð Rated rpms 1800/min or 2000/min
with peak pressures of up to 1,800 bar
ð Low service requirements
ð Electronic engine management (EC) with engine-proof electronics and long maintenance intervals, with long distance journeys up to
extensive engine protection functions 120 000 km
ð Direct injection with centrally arranged 8-hole or 6-hole injection easy maintenance; engine oil and fuel filter fitted On the front
nozzles maintenance-free belt drive
ð 4-valve technology ð Operation with FAME / RME (rape seed oil methyl ester) or biodiesel
possible, the engine oil change intervals must be halved
ð Standard constant throttle pneumatically actuated
ð High reliability and long runtime (cylinder head faces selectively
ð Usable engine braking speed way above the rated rpms up to 2300/min
inductively hardened, cylinder head gasket "beaded gasket", low-wear
ð Covers the emission legislation EURO 2 and. EURO 3 material on the intake valves and valve seat rings)
ð Turbocharging with charge air cooling ð Low number of parts because the 6 and 8 cylinder engines have many
ð V8 with 2 turbochargers and engine-side exhaust joining to an engine common parts
braking flap ð Engine power take-off from the rear from plant
ð Preinstallation for retrofitting Frigoblock
ð EURO 3 engines with 5 eco-points
ð 4 eco-points can be supplied in connection with codes MZ0, MV3,
MV4 . . .)

BR 500 Technical Features 95
Technical Details BR 500 in the ACTROS Model 930-934 02.09.2004
Engine model / Power Maximum High torque Displacement Code* Stroke / Engine weight
specification at 1800 1/min torque rise bore dry
kW/PS Nm % cm³ mm kg
OM 501 LA 230/313 1530 (1100/min) 25.4 MX1

EURO II 260/354 1730 (1100/min) 25.4 11 946 MX2 150 / 130 885
(for export) 290/394 1850 (1100/min) 20.3 MX3
315/428 2000 (1100/min) 19.7 MX4
235/320 1650 (1080/min) 32 MV1
OM 501 LA 265/360 1850 (1080/min) 32 MV2
EURO III 300/408 2000 (1080/min) 26 11 946 MV3* 150 / 130 940
320/435 2100 (1080/min) 24 MV4*
335/456 2200 (1080/min) 24 MX0**
OM 502 LA 350/476 2300 (1100/min) 23.9 MX5
EURO II 390/530 2400 (1100/min) 16 15 928 MX6 150 / 130 1125
(for export) 420/571 2700 (1100/min) 21.1 MX7
370/503 2400 (1080/min) 22 MV6*
OM 502 LA 395/537 2500 (1080/min) 19 15 928 MV7 150 / 130 1250
EURO III 425/578 2700 (1080/min) 20 MV8
* with code MZ0 only 4 eco-points for alp transit through Austria.
** MX0 not available for all-wheel drive vehicle.

Technical Details BR 500 in the ACTROS Model 930-934 96
Performance Graph in the ACTROS Model 930-934 02.09.2004
Engine output diagram EURO III
Die specific fuel consumption curve should only be

regarded as an approximation value.
N01.00-2380-73 N01.00-2381-73

Performance Graph in the ACTROS Model 930-934 97
Engine: Oil Circuit 02.09.2004
Lubricant circuit
A gear-type oil pump with a 43 mm wheel width

for the V6 engine or 49 mm for the V8 engine
supplies the lubricantion and cooling circuit.
The gear type oil pump is bolted in the area of the
rear crankshaft end on the crankcase and is
driven by the crankshaft gear over the oil pump
drive gear.
An integrated pressure control valve keeps the oil
pressure constant or limits it.
All oil ducts are integrated in the engine housing,
only the turbocharger is supplied with lubricating
oil by external screwed-on cables.
A check valve is fitted close to the oil pump in the

main oil duct from the oil pump to the heat
exchanger. This prevents the of filter and oil ducts
running empty and thus ensures a fast pressure
build-up on the bearing points.
N18.00-2011-50

Engine: Oil Circuit 98
Task 1
¦ Assign the parts in the illustration to the
corresponding numbers!
Use the workshop literature provided.
The following parts are integrated in the die-cast

aluminium housing of this mounted unit:
1 Full-flow oil filter

2 Filter evacuation valve
3 Filter bypass valve
4 Oil temperature sensor
5 Oil pressure sensor
6 Oil-water heat exchanger (flat tube)
7 Coolant temperature sensor
8 Connection for bypass filter (exit)
9 Connection for bypass filter (entrance)
10 Riser
11 Connection for filling the oil circuit
N18.20-2020-05

Task 2
With which operations on the parts listed below must a external filling of the
oil circuit take place?
a Cylinder head gasket replacement

b Unit pump exchange
c Cylinder head compressor replacement
d Injection nozzle replacement
e New bearings on crankshaft
f Connecting rod replacement
g Turbocharger exchange
h Oil filter replacement
i Oil filter housing removal, fitting
j Oil pressure switch replacement
k Oil cooler exchange
l Oil sump gasket replacement
m Oil pump removal, fitting
n Oil spray jets exchange
Task 3 W18.00-0003-06
With which pressure must the oil circuit be filled?
1 Screw plug (M33x2)
a 0 - 2 bar 2 Sealing ring
b 2 - 4 bar 3 Adapter
c 5 - 10 bar 4 Oil replenishing canister
d 10 - 20 bar 5 Shutoff valve

Cyclone separator function principle
The blow-by gases from the crankcase arrive at the cyclone separator insert
as precleaned raw gas.
The cyclone separator insert consists of two cyclones.
The raw gas enters the cyclone from the side (tangentially). In the suction
chamber, the gas stream is forced in a downward flowing spiral movement.
The centrifugal force forces the floating oil particles to the cyclone wall, where
they slide down with gravity, supported by the downward movement of the
gas, to the conical (tapered) surfaces of the swirl chamber. The oil exit takes
place through a bore at the lowest point of the cyclone.
Because the cyclone tapers conically downwards, the circumferential speed

and the centrifugal force become increasingly greater so that even smaller
particles are captured by the separator in the lower area. The revolving,
whirling gas changes direction upwards at the lowest point of the cyclone and
is led away upwards through an outlet pipe (take-off tube) as pure gas.
The diameter and the conical shape of the take-off tube determines the
amount of pressure loss and the filtration efficiency of the cyclone.
The bypass valve opens on high gas flow.
GT01_20_004_C12

Engine Crankshaft Seal Front and Rear BR 500 02.09.2004
A radial shaft sealing ring with a PTFE sealing lip and a felt dust lip is used to seal both the front and rear crankshaft. The dust lip prevents the ingress of dirt
particles and thus increased wear. Due to the high wear resistance of the PTFE material and the wide contact surface, mating rings on the front as well as the
flywheel side are not needed.
There are two repair solutions for remedying leakages:
1. The fitting of a new radial sealing ring with PTFE lip analogous to the series.
2. With repairs due to run-in crankshaft/flywheel is, a radial sealing ring with an increased inside diameter is to be used. For this, as with the BR 400
engines, a corresponding race must be shrunk on, which is contained in the parts list.
Front crankshaft seal N03.30-2006-05 Rear crankshaft seal N03.30-2005-12

Engine Crankshaft Seal Front and Rear BR 500 102
ACTROS Model 930-934 Cooling System 02.09.2004
Efficient cooling system
The cooling system of the ACTROS corresponds basically to that of its predecessor. However, it has been oriented to the increased power of the Euro-3 engines
and given an improved cooling-air flow. The cooling system consists of, among other things:
· The tightly-meshed insect protection grille, which is now only fixed to the radiator.
· The condenser (only with air conditioning) of corrosion-proof aluminium alloy.
· The charger air cooler.
· The coolant air cooler with 2-chamber coolant compensation reservoir. Both of the two chambers are protected by a pressure relief valve. The coolant
temperature is monitored by a one-speed coolant sensor. The transmission oil coolant cooler is integrated in the lower part of this system - as standard or
special equipment (N55).
· Dumpers, flatbed vehicles and semitractor trailers (4x4 and 6x6) with V6 engines and a permissible gross weight between 80 t and 120 t are fitted with the
cooling system from the V8 engines (code MP2, improved cooling system), providing the major assembly dimensioning makes this possible.
The package contains: The transmission oil cooler or the electromagnetic fan clutch.
· The fan shroud (with recirculated air separation on V6, without recirculated air separation on V8) with special inlet nozzle for the specific air ducting to the
jet ring fan fitted on the engine, which has been fundamentally reworked.

ACTROS Model 930-934 Cooling System 103
Testing the Cooling System for Leaktightness 02.09.2004
Task 1 m The coolant circuit can be tested for leaktightness with a pressure test. Determine which statements
are true for testing the coolant system pressure for leaktightness. Use the available WIS literature
Gruop 20.00 for this!
a The test takes place at the filler neck

b The test pressure may not exceed the cover pressure
c The test pressure is approx. 1.0 bar
d The test pressure is approx. 1.2 bar
e A pressure decrease within approx. 5 to 10 minutes is tested for
f The heating should be switched off
g The heater control should set to maximum
W20.20-3001-01
Task 2 m Name possible defects that can be localized with a coolant pressure test?
a Water pump seal, leaky radiator

b With wet cylinder liner, leakage of the O-rings
c Cracks in the cylinder head, leakage of the cylinder head gasket
d Leakages in the air compressor area (water-cooled)
e Leakages in the oil cooler
f Leakages in the retarder cooling system
g Leakages on the hose connections of the cooling system
h Leakages in the injection nozzle protective sleeves

Testing the Cooling System for Leaktightness 104
Fan types / design
Fan drive
· Viscous fan clutch: · High-speed fan: · Electromagnetic fan clutch:

The classic viscous fan clutch, which allows, due All V8 engines in the Euro-3 version are The 3-stage electromagnetic fan clutch of the
to an extensive overworking, an approx. 6 equipped as standard with a high-speed fan 2nd generation can be switched in and out with
percent higher rate of air flow, thus significantly (ML3). The belt-driven high-speed fan drive a permanent magnetic clutch using the eddy
improving the power of the cooling system . The (ML3) ensures an increased cooling power. current principle. This clutch is connected to the
noise level of the fan could also be reduced by front end of the crankshaft (= engine rpm) with
2.5 dB (A). an elastic hub. The maximum transferable torque
of the clutch is 170 Nm, its weight 13.3 kg
N20.40-2028-10 W13.22-1007-06 W20.40-1004-05

Testing the Cooling System for Leaktightness 105
Engine: Valve Setting 02.09.2004
Valve Drive
The improved gas exchange, achieved through the 4-valve technology,

mainly contributes to decreased fuel consumption with
correspondingly favorable emissions.
The control of the intake and exhaust valves takes place through roller
tappets guided by a sliding block in a groove in the crankcase, push
rods and intake and exhaust rocker arms, which each operate the
exhaust and intake valves with a valve bridge .
The rocker arm spindle is bolted complete with preassembled rocker

arms and rocker arm bushing on the cylinder head.
To reduce the wear of the entire valve gear to a minimum over the full
life-span, the contact surfaces of the valve, valve bridge, rocker arm
tappets as well as the upset push rod ball socket and height adjusting
screw nail head are inductively hardened to absorb the operating
forces of the high-temperature valve springs and the effective inertia
forces and cylinder pressures.
N05.30-2001-50

Engine: Valve Setting 106
Valve Play Adjustment BR 500 02.09.2004
The valve play testing and setting has not changed for the BR 400. There are 2 methods.
Method 1
Adjust the intake and exhaust valves for each cylinder according to the injection sequence.
The cylinder to be adjusted must be in ignition TDC, the parallel cylinder in overlap TDC.
With this method, the crankshaft must be turned six times on a 6-cylinder and eight times on an 8 -
cylinder engine.
Method 2
Adjust the intake and exhaust valves in two crankshaft positions.
Adjust when the 1st cylinder is at FB in ignition TDC.
Adjust when the 1st cylinder is at FB in overlap TDC.
N05.30-2077-01 P
Task 1 m In the illustration mark with an arrow the place where the valve play is tested.
Valve Play Tolerance
Intake 0.40 + 0.20 / - 0.10

Exhaust 0.60 + 0.20 / - 0.10
The valve play test tolerance applies only for the test of the valve play.
If the valve play is outside the tolerance range, the specified value must be set.

Valve Play Adjustment BR 500 107
Task 2 m You want to adjust the valves on an ACTROS model 930 with OM 501 engine using method 2.
Using WIS cross the correct points for this!
a Set the 6th cylinder to ignition TDC
b Set the 6th cylinder to overlap
c Set the 1st cylinder to ignition TDC
d Set the 1st cylinder to overlap TDC
N01.00-0200-01
Engine Crankshaft position Cylinder / valves to be set

1 2 3
4 5 6
7 8
6-cylinder 5th cyl. valve overlap I/E E I E
- I
1st cyl. valve overlap - I E

I I/E E
8-cylinder 6th cyl. valve overlap I/E E I I

E -
E I
1st cyl. valve overlap - I E

E I I/E
I E
N01.00-0201-01
Legend:

E intake valve
A exhaust valve
X flywheel side

Notes:

Engine: Engine Brake 02.09.2004
A constant throttle valve is fitted in each cylinder as the "fifth valve".

The actuation takes place pneumatically from the bolted connection. The
pressure chamber is sealed upwards with an O- ring in the cover. The
cover is fastened in the cylinder head housing with a retaining clip.
N01.50-2001-50

Engine: Engine Brake 111
Operating method
1. The constant throttle is permanently open after switch on.
2. On the compression stroke (2nd stroke), only a little air escapes during the fast piston movement from the bottom to the top reversal point through the
constant throttle in the outlet duct. The desired compression force is thus achieved.
3. During the brief stop of the piston at top dead center the compressed air escapes mainly through the constant throttle into the outlet duct.
4. Without constant throttle the expansion of the compressed air aids the now downward movement of the piston (3rd stroke) and almost completely recycles
the compression work of the 2nd stroke. For this reason, it provides no noticeable contribution the engine braking power on conventional engines.
Conversely, the pressure on the piston is much lower on an engine with constant throttle in the 3rd stroke. The usable difference from compression and
expansion work is thus significantly greater and thus also the contribution to the engine braking power.
5. Through the effect of the constant throttle together with the standard engine braking flap, the undesirable reopening of the exhaust valve is entirely
prevented. This significantly relieves the exhaust valves.
6. No engine ignition takes place when the constant throttle is switched on. To avoid an unintended engine switch off, e.g. through incorrect operation, the
constant throttle and engine braking flap are automatically switched off at an rpm of under 900 1/min.

Arrangement and engine braking power
N01.50-2009-02 N01.00-2429-50
Task 1 m Using the diagram, determine the engine braking power of the OM502 engine at an rpm of 2100
1/min and note it down
-
The line-specific engine braking power could be further increased in comparison to the BR 400 through the optimization of the constant throttle
cross section on the new swept volume of 2l/cylinder and a new design of the engine braking flap (one-sided stop of the engine braking flap).

Pump-Line-Nozzle Injection System 02.09.2004
Arrangement of the unit pump
The injection takes place from the Pump Line

Nozzle (PLN) system, actuated by the Telligentâ
engine management system.
With the PLN system, the fuel is delivered to the
injection nozzle using individual unit pumps through
short, relatively stiff high-pressure injection lines
and the pressure pipe connections bolted in the
cylinder head.
Each cylinder is assigned a unit pump fitted in the
crankcase. This are driven by a further timing cam
on the camshaft. The camshaft thus takes over, in
addition to the classic task of controlling the intake
and exhaust valves, the drive of the unit pumps.
The working principle of the unit pump is also based
on the piston pump principle as the previously used
in-line injection pump, although without control
edges on the pump plunger.
The amount injected is determined cylinder-
selectively with solenoid valves controlling the
injection start and injection end.
N07.02-2018-50

Pump-Line-Nozzle Injection System 114
Unit Pump: Designation and Delivery Phases 02.09.2004
Task 1
¦ Assign the numbers in the illustration to the

terms in the table
Camshaft
Unit pump magnet

Pump plunger
Suction gallery
High pressure cylinder
Roller tappet
Valve body
Unit pump head
Pressure line
Injection nozzle
Pressure pipe
High pressure chamber
N07.15-2031-06

Unit Pump: Designation and Delivery Phases 115
PLN Injection Control 02.09.2004
Injection start control function
When installing a new injection pump, the delivery start mark previously had
to be observed. The start of delivery was set by a mechanical setting in the
rpm area. A mechanical injection timing device at high rpm moved the start of
delivery of the injection pump in "advanced" direction.
When fitting a unit pump, no start mark and setting is necessary.
Start of delivery
The EC/PLN control module controls start of delivery by moving the time of
the injection start order in relation to the ignition TDC of the cylinder to be
filled. The start of delivery can be entirely freely controlled by the EC/PLN
electronics within the mechanical limits (limited by the cam shape). The limit
values for this engine (max. start of delivery 25° before to 5° after TDC) are
stored in the control unit.
The control unit recognizes from the rpm sensor (TDC sensor, crank angle
position sensor) the phase in which each individual cylinders is located. The
closed recognition (S) is the second necessary reference mark for control of
the actual injection start. The time delay between electrical and actual
injection start is compensated for by the performance map control in he
control unit.
Diagram 1: El. injection start 5° before TDC

Diagram 2: El. injection start 5° after TDC
W07.15-0037-06

PLN Injection Control 116
Delivery volume control function
Previously, the delivery volume was set by a complicated, precise mechanical

specification in the injection pump. With complaints in this area, e.g. lack of
power, costly test procedures and testing devices (injection pump test bench)
were necessary to carry out the complicated adjustment.
With EC/PLN, only the critical limits are set by the mechanical unit pump
where the electronic control can take place. The max. control range is
determined by the stroke of the unit pump cam (approx. 65.5 ° camshaft) and
the max. volume range by the corresponding displacement volume in the high
pressure cylinder.
Delivery angle
The angle through which the crankshaft has rotated on a running engine from
the start (S=close recognition) to the end of a delivery stroke (the valve
opens) is the delivery angle (A). During this time, the camshaft is only turned
by half the crankshaft delivery angle.
The EC/PLN control module determines the injection period and thus also the
amount injected from the delivery angle (pulse width).
In diagram 1, the electrical injection start begins with the close recognition (S)
5 ° before TDC. With a delivery angle of 10° crankshaft the delivery stroke 5°
after TDC (diagram 2). The actual angle change of the crankshaft is acquired
from the rpm sensor on the crankshaft (signal comes every 10°).
W07.15-0036-06

Delivery phases of the unit pump
Task 1 m The operating method of the unit pump is determined by 4 delivery phases.
N07.15-2024-11 N07.15-2025-11

Arrangement of pressure pipe connection, nozzle holder assembly and nozzle protection sleeve
The pressure pipe connection with integrated pin-type filter forms the connection of the high-pressure injection line to the vertically and centrally arranged nozzle
holder assembly with the injection nozzle.
The nozzle holder assembly sits in a nozzle protection sleeve and is bolted in the cylinder head with a clamping claw. The sealing against the combustion gases
takes place with a copper sealing ring.
The nozzle protection sleeve itself is sealed against the coolant with an O-ring and on the pressure side by the thread and the surface area.
Legend:
1 Injection line
2 Leak fuel line
3 Pressure screw
4 O-ring
5.1 Pressure pipe connection with anti-twist
lock (pressed-in ball)
5.2 Pressure pipe connection without anti-
twist lock
6 Nozzle holder assembly
7 O-ring
8 Bolt
9.1 Retaining clip (up to engine end no.
106096)
9.2 Retaining clip (from engine end no.
106097)
10.1 Sealing ring (up to engine end no.
197928)
10.2 Sealing sleeve (from engine end no.
197929)
11 Constant throttle cover
12 Adapter
13 Extractor
L Shank length of the bolt (8) W07.03-1018-06 W07.03-1019-06

Unit pump removal, sealing and fitting
Task 2 m Remove unit pumps, but first look at how it goes. Which precautionary measures must be met? Refer
to the workshop literature and cross the correct information!
a Loosening and removing the multithread screws takes place in one step.
b Remove the engine wiring harness from all unit pumps.
c Loosen the multithread screws by approx. 6 mm.
d Turn the crankshaft with rotary device until the unit pump cam on the camshaft has pushed out the
unit pump.
e If the unit pump sticks in the housing lever out with a lever under the solenoid valve.
f If the unit pump sticks in the housing remove carefully with the nozzle drift tool.
g Once the pump is free, remove the multithread screws and the pump.
Task 3 m Fit unit pump, but first look at how it goes. Which precautionary measures must be met? Refer to the
workshop literature and cross the correct information!
a Turn the crankshaft with rotary device until the pump cam points towards the unit pump.
b Only replace the O-ring when it is damaged.
c The pump can only be fitted when the camshaft is in the base circle.
d Before fitting the unit pump, replace the O-ring (special tool).
e Lubricate the O-rings with mounting grease before fitting the unit pump.
f Pull the unit pump into its seat with the bolts and tighten them.
g Press the unit pump by hand against the spring load into the crankcase,
(distance approx. 4 mm).
h Press in the unit pump by hand as far as possible. Overcome the remaining distance by turning the
bolts and tighten with the specified torque.
i The connection sequence of the electric cables does not have to be observed.
j The cables must be mounted to the solenoid valves exactly as specified.
k After replacing a unit pump, unit pump classification must be carried out.
s
Notes:

Fuel Circuit 02.09.2004
Symbolic Fuel Circuit

The low pressure fuel circuit has especially redesigned for the requirements of the high-pressure injection system with individual unit pumps on the V engines. In
contrast to conventional injection systems, a high pre-pressure in the low pressure system and a large flushing volume for cooling the control valve magnets in
the unit pumps are required.
Task 1 m Complete the legend!
III
15 I Fuel pump
II
III
16
IV Unit pump
IV
VI Pressure maintaining valve 2 bar
19 I II
11 Fuel tank
17
18 12
13 Manual pump
14 Fuel heat exchanger
VI 15
14
16
17 Bypass throttle
18 Bypass valve
19 Pressure limiting valve 9.5 bar
12 13
11

Fuel Circuit 122
W07.15-1080-09

Fuel Circuit 123
Parts
1 Fuel tank B10 Fuel temperature sensor
1.1 Fuel strainer (800my) R3 Flame glow plug
2 Fuel prefilter (FPF 300my) with manual fuel feed pump Y5 Flame starting system solenoid valve
3.1 Plug-on valve on the fuel filler neck (locked in open position)
3.2 Plug-on valve in the fuel return line (locked in open position) Fuel circuit
4 Fuel heat exchanger A Fuel feed line/suction side
5 Fuel pump (FFP) B Fuel feed line/pressure side
5.1 Pressure relief valve (9.0 -12.0 bar) C Fuel high pressure side (injection line) after PLN unit pumps
6 Fuel filter (FF 1.5 my) D Fuel return line after unit pump
6.1 Fuel filter evacuation valve E Fuel flushing volume (fuel bYpass)
6.2 Permanent ventilation in FF (0.7mm) F Fuel return line/leak fuel
7 Nozzle holder assembly
8 PLN unit pumps (Y6 to Y13) Test points, test data
9 Ring-piece with permanent balance hole (0.7mm) G Pressure gauge test
10 Overflow valve (up to engine no. 092407 2.0 bar, H Fuel return volume test
from engine no. 092408 2.65 bar
10.1 Throttle (3.1mm) in overflow valve
11.1 Fuel filler neck connector (in frame) - - - Fuel channels in ZKG
11.2 Fuel return line connector (in frame) ----- Fuel lines
12 Throttle (0.5mm) in the fuel line flame starting system
Task 2 m At test points are the following tests made? Assign them!
Test point Fuel test

System pressure in low pressure circulation after filter
Fuel return volume to fuel tank
Low pressure fuel circuit leaktightness
Fuel suction pressure of the fuel pump
Air bubble formation in the intake line
Fuel return volume (leak oil quantity) nozzle holder assembly with pressure pipe connection

Fuel Circuit 124
Task 3
m The graphical illustration of the "symbolic fuel circuit" shows several parts in the
fuel filter housing.
In the illustration, mark the following parts with ...

1 for fuel filter evacuation valve and
2 for permanent ventilation. 1
1 from fuel tank

2 to unit pumps 2 3
3 return line to fuel tank
N07.15-2044-01
Task 4 m The riser in the fuel filter housing possibly looks like a simple invention. It is actually used for several
purposes.
Use the table below and cross the correct tasks of the riser.
a To clean the fuel
b Fuel filter housing with positive ventilation
c To allow a cold start of the engine
d It is the fuel filter holder
e It is an aid for the fuel filter and protects it from overflowing
f Contains die maintenance release bore (fuel filter evacuation valve)
g Adjustment to the riser to deliver the fuel so that the entire length of the fuel filter can be used, which
means a larger filter area and thus with a greater effect
h Prevents the necessity of a prefilter

Fuel Circuit 125
Fuel Prefilter with Heated Water Separator, Code K81 02.09.2004
To prevent a premature blockage of the standard

filter, an additional fuel prefilter can be optionally
ordered. This is fitted in the line between the fuel
tank and fuel pump and filters large particles
before the standard filter.
If present, free water in the fuel is held back in
the lower part of the prefilter housing and must
be released from time to time. To prevent the
held-back water from freezing at lower outside
temperatures, is the collection container is
heatable.
Example: BR 500 W47.20-1011-05
Area of operation:
In countries, where with greatly soiled fuel and high water content is expected, an additional fuel filter with integrated heat water separator (incl. manual pump)
is absolutely recommended.
Vehicles, operating in eastern Europe or that are to be filled with fuel from these regions should absolutely be fitted with the prefilter.

Fuel Prefilter with Heated Water Separator, Code K81 126
Telligent 02.09.2004
The control of the engine, the engine management, is divided into two partial systems each with its own control unit. The control unit of the Drive Control
(DC/VEC) partial system is vehicle-related and that of the Engine Control (EC/PLN) partial systems is motor-related.
All engine-specific data is stored in the EC control unit. The engine-related operating conditions are determined from various sensors. These are evaluated and
the injection is actuated corresponding to the DC requirement (specified engine torque) reflecting the stored performance maps.
The DC control module contains, among other things, vehicle-relevant data, determines the vehicle operating conditions and receives the operation of the driver.
For example, this can be the pressing of the accelerator pedal, operation of the service or engine brake, or clutch.
From this the DC control module determines the required engine torque and passes this on as the specified engine torque to the EC.
Depending on the vehicle configuration, further software modules are integrated in the DC.
The communication exchange between DC and EC takes place over CAN 4, to GS over CAN 5 and to other vehicle-related control units over CAN 1.
You will ask yourself, "Why actually separate systems"?

Let us speak about the reasons and the advantages that result from them.
· Modular design, allowing individual adjustment and development possibilities.

· The drive control also covers "engine-foreign" functions and can be designed version-specifically.
· Vehicle-specific data (e.g. neutral, operating rpm etc.) remain in the vehicle after an engine replacement.
· The engine control module and engine data matching the engine remain on the engine. They are thus engine-bound.
· Reconditioned assemblies always have the latest engine data.
· Fault diagnosis is easier because processes c<an be assessed separately.

Telligent 127
Telligent Engine System Distribution; Exercise 02.09.2004
Task 1 m The reasons for system distribution might appear plausible but how does it look with the assignment
of the tasks? To get a better feeling for this we have listed some tasks, which are to be assigned to
the individual systems.
Task assignment
Actuation of engine braking flap solenoid valve
Constant throttle solenoid valve actuation
D Determine oil level ð E
R Assign injection time and amount injected N
I Acquire and process driver wish G
V Limit rpm I
E ï Forward engine start signal ð N
Control cruise control and limiter E
C Initiate alternator preexcitation D+ (not on compact alternator)
O Forward coolant temperature C
N System monitoring, fault evaluation and fault code formation O
T Evaluate current operating conditions of the engine N
R ï Control overspeed warning T
O Activate emergency operation program R
L Activate engine protection functions, such as boiling protection O
Determine engine coolant level L
Activate engine start/stop function (MSS) (ATEGO only)
Evaluate transponder code
Control of the transmission splitter group on HPS / MPS

Telligent Engine System Distribution; Exercise 128
Operating Modes on the Engine Control / Permanent Brake Control Operating Lever 02.09.2004
On MB vehicles, the following operating modes can be selected with the "engine control / permanent
brake control" operating lever. The operating modes available on the vehicle are dependent on the vehicle
model and chosen SE option.
§ Cruise control
§ Limiter
§ Permanent brake in stepped mode
§ Permanent brake cruise control
§ Combined drive/brake cruise control
§ Telligent adaptive cruise control
§ Engine idle speed up
§ Working speed control
W54.25-1035-11
Note:
On the ACTROS model 930-934 the operating modes cruise control and permanent brake cruise control are not implemented. The combined drive/ brake cruise
control is offered as standard. In the literature (operating instructions), the combined drive/ brake cruise control is still designated as cruise control. Optionally
this mode can be complemented with the TelligentÒ distance control (ART).

Operating Modes on the Engine Control / Permanent Brake Control Operating Lever 129
Effects, that the respective operating modes have on the vehicle behavior
Cruise control: Keeps the commercial vehicle speed constantly "down under", without the driver having to constantly use the foot throttle actuator (a type of
"automatic" accelerator). The cruise control does NOT prevent that the speed in deceleration operation increases above the set value.
Limiter: Adjustable maximum speed. Limits the speed to the set value in fired operation, i.e. the foot throttle actuator is operated no further speed increases
occur from the set speed (except with kickdown). with the ACTROS model 930-934, the limiter is additionally overlaid with the brake cruise control mode in
the non-fired operation.
Permanent brake in stepped mode: Decelerates commercial vehicle. The brake power is produced by speed-dependent engine-brake systems such as the
engine braking flap, constant throttle, Turbobrake (optional) and through a speed-dependent retarder (optional). The effect of the engine brake rises with
the engine rpm.
Permanent brake cruise control: Keeps the speed of the commercial vehicle constant - as far as possible - "upwards" using the permanent brake constant.
Combined drive/brake cruise control: Is the combination of cruise control and permanent brake cruise control. This mode ensures automatic acceleration as
well as for automatic deceleration of the vehicle, as soon as actual speed deviates from the selected speed. The control speed of the permanent brake
cruise control lies slightly (approx. 4 km/h) above the cruise control speed selected by the driver. This ensures that the permanent brake cruise control is
not immediately activated , as soon as the vehicle accelerates slightly above the selected speed. Inversely, the cruise control is not immediately active
when the vehicle speed goes slightly under the control speed.
TelligentÒ distance control (ART): Is an extension of the combined drive/brake cruise control. It not only automatically keeps the selected speed, but also,
additionally, ensures that the selected minimum distance to the vehicle in front is not fallen below. If the distance is too short a deceleration of the
commercial vehicle takes place without the driver having to act. As soon as the distance is sufficient again, the commercial vehicle automatically
accelerates to the selected speed.
Engine idle speed up: Allows the idle speed to be increased on a stationary vehicle, e.g. for the faster filling of the service brake.
Working speed control: Sets a fixed variable engine speed, without the driver having to constantly operate the foot throttle actuator. The working speed control
is used to drive ancillary assemblies on a stationary vehicle.

Operating Modes on the Engine Control / Permanent Brake Control Operating Lever 130
ACTROS Model 930-934 Drive Systems Operational Concept 02.09.2004
Switching between the limiter, cruise control,

and ART operating modes
The switching or preselection is possible

stationary and on driving vehicles.
TM FR Fahrsysteme 1_D.PPT

ACTROS Model 930-934 Drive Systems Operational Concept 131
ACTROS Model 930-934 FR Drive Functions Operating Modes 02.09.2004
Task 1 m Various operating modes can be accessed through the engine control / permanent brake control
operating lever.Arrange these correspondingly in the table!
Use the following main questions for this:

- Which control is activated by the corresponding mode?
- What influence on the driving mode does the corresponding operating mode have?
- Which control values are activated by the corresponding mode?
Functions Control of ... Effect on the vehicle: Control values:

n v s Acceleration Deceleration by Deceleration by v v n
permanent brake service brake constant maximum constant
Limiter
Cruise control (combined
drive/brake cruise control)
Permanent brake (stages)
TelligentÒ distance control (ART)
Engine idle speed up --- --- ---
Working speed control --- --- ---
n-control rpm regulation

v-control speed regulation
s-control distance control

ACTROS Model 930-934 FR Drive Functions Operating Modes 132
Practical - Engine 02.09.2004
Task 1 m EC-relevant parts on the engine BR 500 are arranged in the illustration below and also on the following
page. Identify them through assignment of the corresponding part designations in boxes for them on
the following page.
W07.15-0005-09

Practical - Engine 133
W07.15-0006-09
EC control module (A6) Engine start button (S10) TDC sensor (B16)
Oil pressure sensor (B12) Fuel temperature sensor (B10) Starter (M1)
Charger air temperature sensor (B9) Unit pumps (Y6 - Y ...) Charger pressure sensor (B13)
Coolant temperature sensor (B65) Engine stop button (S11) Oil temperature sensor (B14)
Crank angle position sensor (B15) Oil level sensor (B14) Starter relay

Practical - Engine 134
ACTROS Model 930-934 Teaching In the Foot Throttle Actuator 02.09.2004
The foot throttle actuator can be taught in on-board and with the DAS system.
Task 1 m Teach in the foot throttle actuator on-board?
Display
Requirements: FR LEARN
Enable diagnosis menu in the settings menu (see Start the teach-in process using "Reset with reset key"
operating instructions). ____
Teach in the foot throttle actuator: A___

· Select diagnosis menu
· Select Service info submenu +___
Keep the accelerator pedal at full load
+__A
+__+
Finish the teach-in process using "Reset with reset key"
FR OK
Task 2 m Teach in the foot throttle actuator using the DAS. Note down where this is carried out.
a.) In which system? -
b.) In which submenu? -

ACTROS Model 930-934 Teaching In the Foot Throttle Actuator 135
EC Actuation in DAS; Exercise 02.09.2004
Task 1 m Engine test with Star diagnosis! Is this actually possible Of course! But which test is to be used for
which problem?
Some important engine tests are listed. Discuss in groups possible complaints or problem cases,
which can be detected and tested with these engine tests! Assign the found complaints to the tests!
Engine test Usage, possible complaint and problem cases
Single cylinder failure
Test of compression
Test of the idle running control
Test for incorrect polarity
Test of the single cylinder adjustment
Test of the proportioning solenoid valve
Test of the Linnig fan

EC Actuation in DAS; Exercise 136
Task 2 m Carry out the required tests and enter the results.
Test of compression: Test of smooth running control:
Cylinder 1 % Cylinder 1 %

EC Actuation in DAS; Exercise 137
Unit Pump Classification 02.09.2004
Unit pumps of the BR 500 are classed during manufacture.

ACTROS model 930-934 MR
The class of each individual pump is recorded when fitting to the engine on the
assembly line in Mannheim and stored in the EC control module. Unit pump replacement
To ensure a uniform running engine, these values are reflected on dispensation
Cylinder Code
of the fuel volume (injection times).
1 Cylinder 1 X-XXX-XXX-XX-XXXXX
To ensure uniform engine running also after replacing or swapping the unit 2 Cylinder 2 X-XXX-XXX-XX-XXXXX
pumps, the class of the unit pump must be assigned to the cylinder.
A false input can lead to irregular running engine and overload of 4 Cylinder 4 X-XXX-XXX-XX-XXXXX
individual cylinders! 5 Cylinder 5 X-XXX-XXX-XX-XXXXX
Note:
The user must read the unit pump number on the
unit pump and enter it for the corresponding
cylinder. Only enter the unit pump number of unit
pumps that have been replaced. Press the F3 button
to input.
Note: After unit pump classification, reset the idle smooth running control.

Unit Pump Classification 138
The classification class is in the form of a 14-digit number (C) on the model
plate of the unit pump. The code is entered with DAS in the "Unit pump
exchange" menu.
A = MB number
B = certification number
C = unit pump number
D = bar code
E, G, H = manufacturer information
F = manufacturer bar code
N07.02-2028-01

Unit Pump Classification 139
Telligent Maintenance System (WS) 02.09.2004
· It replaces the usual fixed maintenance intervals with calculated

maintenance dates adjusted to the major assembly loads.
· It allows planned workshop stays by combining various maintenance dates
as well as legally required vehicle inspections.
· It increases vehicle availability with planned workshop stays.
· It supports the planning of vehicle use with the possibility of continuous
readout of the remaining distance or the remaining operating time of all
maintenance dates.
· It protects against damage to the major assemblies by forgotten or delayed
maintenance operations by ensuring a maintenance date with a continuous,
non-deletable visual indicator.
· It immediately reports unusual operating conditions and system errors with
a visual indicator, which may be acknowledged or not depending on the
seriousness. This protects the major assemblies or the operational safety.
· It decreases the maintenance costs and environmental pollution by an
optimal use of resources without endangering the functional reliability and
life of the major assemblies.
· Through extensive self-diagnosis with visual display and fault storage, it
allows the fast capture of data from system errors in FSS/WS-specific parts
and sensors as well as transmission errors received from external signals
over the vehicle CAN bus.

Telligent Maintenance System (WS) 140
Maintenance System (WS) Function Model 930-934 Actros MPII Overview 02.09.2004
W00.20-1037-79

Maintenance System (WS) Function Model 930-934 Actros MPII Overview 141
Legend:
1 With disk brake B41 Brake wear sensor on the 1st rear right axle
2 With drum brake B42 Brake wear sensor on the 2nd rear left axle
A3 FR drive control unit B43 Brake wear sensor on the 2nd rear right axle
A6 ME engine control unit B47 Temperature sensor "transmission oil"
A7 BM base module control unit B48 Temperature sensor "front axle oil"
A20 RS retarder control module B49 Temperature sensor "rear axle oil"
A64 FM front module control unit B50 Temperature sensor "transfer case oil"
A65 RM rear control module B65 Temperature sensor "coolant"
B4 Outside air temperature sensor B66 Temperature sensor "retarder oil"
B7 Air filter monitoring sensor B71 Reservoir pressure sensor "brake circuits 1 and 2"
B11 Temperature sensor "engine oil" B76 Condensation sensor
B15 Crankshaft position sensor CAN 1 Vehicle CAN bus
B16 Camshaft position sensor CAN 2 Interior CAN bus
B17 Speed sensor CAN 3 Frame CAN bus
B36 Brake wear sensor on the 1st front left axle CAN 4 Engine CAN bus
B37 Brake wear sensor on the 1st front right axle CAN 10 Tachograph CAN bus
B38 Brake wear sensor on the 2nd front left axle P2 INS instrument cluster
B39 Brake wear sensor on the 2nd front right axle P2p1 Driver information system
B40 Brake wear sensor on the 1st rear left axle P3 MTCO modular tachograph

Maintenance System (WS) Function Model 930-934 Actros MPII Overview 142
Individual and Combined Maintenance 02.09.2004
· Using the FSS/WS it is possible to adjust maintenance intervals flexibly · Based on lengthy test stand and vehicle tests, the wear reserve, or to DIN
even with constantly changing vehicle load. 31051 the wear potential (AV), can be determined exactly.
· Fixed kilometer intervals, as with conventional maintenance, that inevitably · The wear reserve can be used to the maximum with the WS/FSS without
take the most unfavorable conditions into account are no longer necessary. exceeding the damage limit (SG) and thus without the danger of damage or
increased wear.
The illustration shows the course of the wear potential (AV) of a major assembly to the driven
distance (s).
100% New oil in major assembly and filter replaced

0% Oil consumption
AV Wear potential in %
F Damage limit greatly exceeded, major assembly endangered
s Driven distance in km
SG Damage limit
W00.20-0004-01
Because carrying out individual maintenance operations with regard to the cost and vehicle availability is unpractical, the WS/FSS has the capability to sensibly
combine various maintenance dates.
The WS/FSS-2 offers two variations for this:
· The individual maintenance
· The combined maintenance
Note: The WS/FASS is always set to the individual maintenance from the plant. Alteration of the setting to combined maintenance can only be carried out by a
Mercedes-Benz service station.

Individual and Combined Maintenance 143
Individual Maintenance 1 02.09.2004
The illustration shows the various times for maintenance dates with a new vehicle as an example.
After an inspection, due between 1000 and 5000 km, the existing wear potential (AV) of the assemblies is
determined by the data capture of the WS/FSS dependent vehicle stress. Each of the major assemblies
wear potentials is reached at a different time, in relation to the driven distance (s), the limit "0%".
The WS/FSS shows the wear potential of the individual major assemblies separately.
The customer decide himself according to his service routine on how the due maintenance is carried out.
He can
· have each maintenance operation carried out when it is due,
· have various maintenance operations, whose dates are close to each other, combined,
or W00.20-0005-01
· combine maintenance operations with other workshop events, e.g. with a legally required
inspection.
This procedure is ideal for a vehicle fleet that breaks down maintenance operations into small packages anyway and usually completes these periodically.
Note: Apart from the wear potential, the date of regular and general maintenance operations is also determined by WS/FSS.

Individual Maintenance 1 144
Individual Maintenance 2 02.09.2004
Vehicle fleets that place value on longer maintenance intervals can individually combine any maintenance
operations for any time.
Example:
After 100 000 km a vehicle must go to the workshop (W) for a legally required inspection or because it
must be prepared for a particular use
In this case, the maintenance operations that will soon be required can be determined using WS.
If a maintenance-free driving distance of 50 000 km is required after a workshop date then, as the
illustration shows,
· an engine oil change,
· a transmission oil change
and
· the carrying out of general maintenance operations must be specified in the order.
W00.20-0006-01
Attention: A part of the maximum wear potential (AV) is lost by bringing forward the maintenance dates.
(as the illustration shows, e.g. with the engine oil, this is 40%)

Individual Maintenance 2 145
Combined Service 02.09.2004
Various maintenance dates are combined to a single date in the combined service, similarly to the conventional maintenance with WS.The shortest maintenance
interval always determines the maintenance date.
Compared to the conventional maintenance system, the combined maintenance still has advantages:
· At least one of the assemblies has reached the wear potential of 0%.
· Only assemblies that have a low rest wear potential are combined.
Example:
For operating reasons, a vehicle is to be serviced at 100 000 km (W). As the illustration shows, because a
maintenance-free driving distance of 50 000 km is desired,
· an engine oil change
· a transmission oil change
· a transfer case oil change
and
· the carrying out of general maintenance operations must be specified in the order.
In this example, a negative effect is that the transfer case oil change is brought forward by 50 000 km.
W00.20-0007-01

Combined Service 146
Practical - Maintenance 02.09.2004
Task 1
m The 3rd general maintenance is to be carried on a two-year old ACTROS model 930-934
with Telligent maintenance system. Determine in WIS, the AP number for the
maintenance sheet. Which operations are to be carried out with this maintenance? Cross
the correct answer. Use the maintenance sheet to help you.
-
a Adjust valves
b Extra work with J2, lubricate the spring shackle bolt on the leading axle.
c Replace coolant
d Replace air drier granulate cartridge
e Replace the wheel hub grease on the leading and trailing axle N00.10-2158-01
Task 2 m On which maintenance service on an ACTROS with Telligent maintenance system does the fuel filter
have to be renewed?
a On each maintenance service
b On every 1st; 3rd; 5th etc. maintenance service
c On yearly additional operations
d Every 2 years
Task 3 m After replacement of the fuel filter, the fuel system must be vented.
Which procedure is correct?
a Actuate the engine starter until the engine starts.
b Pump with the manual fuel feed pump until the overflow valve audibly opens.
c Open the bleed screw, pump with the manual fuel feed pump until the fuel flows out without bubbles.

Practical - Maintenance 147
Task 4 m The poly-V belt has to be tested on the yearly extra work J1 for wear and condition. For better
assessment of the poly-V belt, there are damage pictures illustrated in WIS under
AP13.22-D-1351-01A.
Cross the illustrated damages shown here!
a Wear on flanks
b Transverse cracks
c Rib has come away
d Pull cord torn out sideways
e Deposit of dirt/stones
f Ribs torn out
N13.22-2066-01 N13.22-2070-01

Task 5 m Remove the poly-V belt from the belt tensioner and fit it again. The procedure is described in the
owner's manual.
Use the necessary vehicle tool kit to do this.
Task 6 m A customer has discovered that in a new area of operation instead of the original low-friction oil in the
specification on sheet 228.5 only the oil in the specification on the sheet 228.3 is available. What
would you advise your customer?
a The maintenance intervals become shorter.

b The maintenance system has to be adjusted.
c the selected MB oil specification can be entered "Onboard".
d The oil specification can only adjusted in the workshop using the STAR diagnosis.
e Operation with this oil specification is not permissible.

Task 7 m After finishing the maintenance operations, the operations carried out must be confirmed or reset in
the service menu.
Cross the correct points that can be changed or reset in the service menu!
Attention: Do not confirm or reset maintenance on the training vehicle!
a General maintenance
b Engine oil change
c Engine oil filter change
d Transmission oil change
e Rear axle oil change
f Retarder oil change
g Test oil quality for SAE class and change if necessary
h Valves adjustment
i Fuel filter change
j Air drier granulate cartridge

TIPS - General 02.09.2004
What is TIPS?
TIPS is a universal DP system for the worldwide exchange of technical information, knowledge and solutions for all service stages (workshops, CAC Maastricht,
MPC/GV, GSP/T as well as plant service) in Internet technology, for the support of guarantee & goodwill cases.
TIPS supports the four business processes of product service, product reliability, technical service in the workshop and 24h service.
Targets of TIPS
· Increase of the after-sales competence in workshops, markets and in CAC Maastricht and thus higher customer satisfaction.
· Increase of the economy in processes to be supported through

- decrease of diagnosis and repair time.
- improvement of the data quality for field information.
- more efficient usage of resources in he MPC/GV workshop support process and in the product service with GSP and in the plant services.
- reduction of guarantee/goodwill costs through early recognition of main damage topüics and their remedy in the product reliability process.
- reduction of incorrectly dismantling/ multiple repairs in the workshop.
· Improvement of the product quality and thus the support of the brand image.
How do I reach TIPS
http://tips-reader.daimlerchrysler.com
User name: Generally valid name published by MPC or plant

Password: Generally valid password assigned by MPC or personally

TIPS - General 152
TIPS - General 153
Chassis: Steering, LS 6 BK, LS 8 BK 02.09.2004
Development goals
The greatly increased requirements for safety, ride comfort, driving characteristics, life-span and maintenance simplification were the initiator for the
development of the Mercedes-Benz power steering LS6, 8 BK.
Since the start of '98, they replace the previous power steering LS 6 and LS 8. The known power steering LS8/2 continues to be manufactured.
From this result the requirement for:
· Optimization of the steering column regarding the location and adjustment range
· Reduction of the track and turning circles
· Decrease of the steering effort while steering when stationary and maneuvering
· Variable gear ratios dependent on the steering angle

-- "directly" when driving straight ahead,
-- "indirectly" with a large steering angle
· Weight and cost optimization of components
· Lower service requirements and thus even higher economy, no exchanges planned in the framework of the maintenance service
· Optimization of the steering kinematics regarding various load cases, such as brakes and jounce with consideration to suspension
and steering versions
· Test connection or pressure fitting for setting the pressure reduction valve and measurement of the system pressure

Chassis: Steering, LS 6 BK, LS 8 BK 154
Steering LS 6 BK, LS 8 BK
Steering worm
Steering shaft
End cover
Ball circuit
Steering shaft
Pistons
Torsion bar
Pressure reduction valve
1. Adjustment screws for limiter
9a. LHD for left

RHD for right
9b. LHD for right

RHD for left
W46.20-0050-09
n
In the video, you see the ventilation of the steering and the setting of the limiter.
Task 1 m Cross which measures are to be met for the ventilation procedure!
a The drag link must be unhitched.

a On left-hand drive (LHD), the bolt no.1 must be screwed in.
a On left-hand drive (LHD), the bolt no.2 must be screwed in.
a On right-hand drive (RHD) the bolt no. 1 must be screwed in.
e On right-hand drive (RHD) the bolt no. 2 must be screwed in.
Note:
The ventilation of the steering is described in WIS AR46.25-W-3300C.
Task 2:
Note down the pressure to which the pressure on the limiter is set!
W46.25-0031-11
1 Limiter adjusting screw
LL left wheel lock (marked with "L")
RL right wheel lock (marked with "R")
2 Limiter adjusting screw
LL right wheel lock (marked with "R")
RL left wheel lock (marked with "L")
3 Oil reservoir
4 Oil dipstick
> s
ACTROS Model 930 - 934 Clutches 02.09.2004
The standard equipping of all engines with single-plate clutch. In conjunction with TCC transmissions (code G02), a single-plate clutch with 445 mm diameter is
used.
The automated clutch operation (code GE2) is only possible with single-plate clutches.
A mixed installation, e.g. Sachs clutch pressure plate and Valeo clutch plate, is not permissible.
Engine without NMV with NMV (N56/N57)

Standard SE (code G81) Standard SE (code G81)
OM 501 LA
1-PC Æ430 mm 2-PC Æ400 mm
(MV1 – MV5)
1-PC Æ430 mm 2-PC Æ400 mm
OM 502 LA
(MV6 – MV8) 2-PC Æ400 mm ---
1-PC = single-plate clutch,
2-PC = double-plate clutch

ACTROS Model 930 - 934 Clutches 157
Changed hub in the clutch plate
On the ACTROS (not on vehicles with strengthened clutch), the hub of the single-plate clutch drive plate is nickel-plated.
In this conjunction, the release bearing on the slide surface is plastic coated and the guide tube precision machined.
Advantages:
· The nickel plating of the hub prevents corrosion on the profile of the transmission input shaft
· Simultaneously, the friction is reduced
· Optimum function of the clutch without the use of grease over the entire life-span
· Due to the discontinued use of grease, the pasting up from clutch abrasion with old grease and the possible malfunctions from that are avoided
· Die altered clutch plates can be recognized by the silvery gloss of the hub
and a different spare part number.
· Due to the nickel-plating of the sliding surface in the clutch drive plate hub
(1), greasing of the hub and the groove profile in the transmission input
shaft (3) is no longer permissible.
· On the double-plate clutch (code G 81 - clutch strengthened) the interior
clutch plate (Attention! Hub not nickel-plated!) may also not be greased.
· Greasing is also discontinued on the guide tube for the thrust bearing (4)
and on the interior slide surface (plastic coating) in the release bearing (2).
· Die above-named facts must be observed even when fitting an altered
clutch plate. The groove profile on the transmission input shaft (3) and the
guide tube (4) must be cleaned beforehand.
· Compare also SI 25.10-W-1000-01A!
Note:
If the "snap effect" occurs on double-plate clutches it is possible for certain
vehicles to be fitted with a single-dry-disk clutch.
N25.10-2021-11

Clutch sensor
A clutch sensor is used on all transmission types on the ACTROS. On the

Telligent shift and the Telligent automatic transmission, the clutch sensor is
evaluated by the GS control unit. The FR receives the clutch sensor data
over the CAN bus. On all other transmission types, the FR evaluates the
clutch sensor directly..
N25.19-2001-01
Clutch booster
The clutch booster piston is moved in the direction of the clutch

when the clutch pedal is depressed. The sensor plunger moves
away from the sensor. The sensor value becomes smaller.
Due to the wear of the drive plate, the clutch booster piston
travels away from the clutch, the sensor plunger dips deeper into
the sensor and the sensor value increases.
1 Connection to the clutch
2 Piston rod
3 Pistons
4 Slave cylinder
5 From master cylinder
6 Clutch sensor
7 Sensor plunger
8 Clutch wear
9 Zero point, clutch closed
10 Clutch open
N25.20-2027-05

Clutch sensor
In the "FR" menu there is, among other things, the "teach in" function with clutch travel sensor subfunction.
You will get to know the tasks and functions with the following questions.
Task 1
m When must the clutch sensor be taught in? Cross them!
a After replacing the clutch
b After the removal and fitting of the transmission
c After maintenance and repairs on the clutch transmission (do not vent)
d After removal and fitting of the engine
e After replacing the FR control unit
Task 2
m Which statements about teaching in the clutch sensor are true? Cross them!
a Clutch closed is recorded on teach in when the clutch pedal is not actuated.
b Clutch open is recorded on teach in when the clutch pedal is fully actuated.
c During teach in, the control unit measures the entire release travel.
d The FR control unit subdivides the taught-in release travel in the three ranges: Clutch closed, operated and opened.
e The FR control unit only recognizes the end points fully opened clutch or closed clutch.

Transmission Overview 02.09.2004
N26.10-0258-50
Transmission designation: G 210
max. input torque (x 10 = Nm)

transmission

Transmission Overview 161
G210 G211/G231 G240 G260
Version Overdrive 1-times Hill/direct drive Overdrive 2-times Overdrive 3-times
Code GC3 GD3/ GH6 GC2 GC1
Model designation 715.500 715.510/715.513 715.520 715.540
1st gear 14.19 17.03 11.72 9.75
2nd gear 11.72 14.19 9.75 8.07
3rd gear 9.58 11.50 7.92 6.58
4th gear 7.92 9.58 6.58 5.45
5th gear 6.50 7.80 5.29 4.40
6th gear 5.37 6.50 4.40 3.64
7th gear 4.40 5.28 3.64 3.02
8th gear 3.64 4.4 3.02 2.50
9th gear 3.22 3.87 2.66 2.22
10th gear 2.66 3.22 2.22 1.83
11th gear 2.18 2.61 1.80 1.50
12th gear 1.80 2.18 1.50 1.24
13th gear 1.48 1.77 1.20 1.0
14th gear 1.22 1.48 1.0 0.83
15th gear 1.0 1.20 0.83 0.69
16th gear 0.83 1.00 0.69 0.57
1st reverse gear 12.90 15.48 10.66 8.86
2nd reverse gear 10.66 12.90 8.86 7.33
i constant slow 1.172 1.172 0.969 0.806
i constant fast 0.969 1.407 0.806 0.667

Notes:

Telligent Shift GSII Code GE7 02.09.2004
The Telligent gearshift system is a driver-relieving shift system, which reduces the ever-growing stress from road traffic.
W26.20-1077-79

Telligent Shift GSII Code GE7 164
Legend:
1 Gate cylindrical actuator CAN2 Interior CAN (redundant)
2 Range cylindrical actuator CAN4 Engine CAN
3 Gear cylindrical actuator CAN5 Transmission CAN
4 Splitter cylindrical actuator KNot K-line emergency running mode
5 Clutch booster P2 Instrument cluster (INS)
6 Multifunction steering wheel S144 Multifunction steering wheel left button group
A3 Drive control (FR) unit incl. drive control (FR) software module S145 Multifunction steering wheel right button group
A6 Engine control unit (EC) Y29 Splitter 1 solenoid valve (MS 1)
A7 Base Module (BM) Y30 Splitter 2 solenoid valve (MS 2)
A15 Gear control (GS) sensor unit Y31 Range 1 solenoid valve (MR 1)
A16 Gear control (GS) control unit incl. gear control (GS) software module. Y32 Range 2 solenoid valve (MR 2)
A90 Gate module Y33 Gate 1 solenoid valve (MT 1)
A91 Range module Y34 Gate 2 solenoid valve (MT 2)
A92 Gear module Y35 Odd air intake solenoid valve (MUB)
B2 Clutch travel sensor Y36 Even air intake solenoid valve (MGB)
B3 Countershaft rpm sensor Y37 Odd venting solenoid valve (MUE)
B17 Speed sensor Y38 Odd venting solenoid valve (MGE)
B60 Gear sensor (SGG)
B61 Gate sensor (SGE)
B62 Splitter sensor (SSP)
B63 Range sensor (SRA)
CAN1 Vehicle CAN
Task 1 m Follow the signal path of the shift control to the gear cylindrical actuator. Complete the block diagram!
- - - -
The Telligent gearshift system shift control contains various functions.

Task 2 m Assign the numbers in the illustration to their function. Use the operating instructions to do this.
Function button
Neutral
½ gear shift down
Upshift
½ gear upshift
Shift down/reverse gear

On the Telligent gearshift system, the driver has various possibilities of changing gear.
Task 3 m Note down the four possibilities.
1. -
2. -
3. -
4. -
Gear indicator:
1 engaged: 8th gear, fast splitter group

2 preselected: 7th gear, slow splitter group

Apart from the shift control unit, the Telligent gearshift system consists mainly of the FR control unit, the gate module with the GS control unit, the gear module
and range module.
Gate module Gear module Range module
N26.20-2018-01 N26.20-2017-01 N26.20-2019-01
Task 4 m In the table, enter the parts fitted in the respective module. Look at the illustration at the start of the
chapter for this.
Component Gate Gear Range Component Gate Gear Range

module A90 module A92 module A91 module A90 module A92 module A91
B60 Y33
B61 Y34
B63 Y35
Y29 Y36
Y30 Y37
Y31 Y38
Y32

Telligent Automatic Transmission EASII Code GE2 02.09.2004
A further improvement in operating comfort is offered by the Telligent automatic transmission. The driver now only has the drive and brake pedals at his disposal.
The clutch is operated by the Telligent automatic transmission. On the EASII the software required in addition to that required by the GSII automatic gear
selection (AG) and the clutch control (KR) is located in the drive control (FR). The software of the clutch operation (KB) is integrated in the transmission control
(GS).
Task 1 m Note down the operating modes to be selected with the operating modes selector switch.
You can find tips in the operating instructions.
In automatic mode, the system always shifts to the optimum gear for the respective driving condition. The driver only needs to press the shift control to start
driving, engage the reverse gear or in shift to neutral. Using the shift control, the driver can change starting-off shifted by the system.

Telligent Automatic Transmission EASII Code GE2 169
Task 2 m On the Telligent automatic gearshift, how can the shift points be influenced?
Use the operating instructions.
The clutch is operated by a electropneumatic clutch actuator. It is mounted on

the left side of the vehicle side on the bell housing.
A93 Clutch actuator

W25.20-1018-11

Clutch actuator design
The clutch actuator consists of following

components, which are all integrated in one
component:
The positioning cylinder is pneumatically

operated, and is responsible for the position
control of the clutch.
Cylinder clutch open

extended
Cylinder clutch
retracted closed
The clutch sensor (SKU = e) captures the

current position of the clutch cylinder.
Measurement value 15 in GS shows the current
clutch travel in %.
Measurement value 20 shows the clutch travel as
a count value.
Clutch actuator, interior design N25.20-2062-05
The four solenoid valves are required to let the correct amount of compressed air to flow in and out of the cylinder.
MKUB1 and 2 clutch solenoid valve pressured 1 and 2 (c; d)
MKUE1 and 2 clutch solenoid valve vented 1 and 2 (a; b)
MKUB2 and MKUE2 (b;d) have a large air duct, they are used for the rough regulation of the clutch travel.
MKUB1 and MKUE1 (a;c) work with a decreased flow area and are used for finely stepped and very exact position regulation of the clutch.

After renewal of the clutch actuator or the clutch, a basic setting of the plunger must be carried out.
2 plunger
W25.40-1076-01
Task 3 m Using the WIS document AR25.20-W-3000A, determine the systematic procedure for setting the
plunger and note down the no. of the required special tool.

Telligent Transmission II, Teach-in Process and Teach-in Faults GS II 02.09.2004
In a teach-in process, the travel values of the travel sensors for the clutch, splitter, range, gear and gate are determined once again and stored in the gear control
unit as learn values. These learn values are stored new for each teach-in process.
Task 1 m On vehicles with Telligent gearshift system (GS II), there are two different teach-in processes.
Find out the corresponding teach-in process to be carried out for which operations.
Cross them! You can find tips in the DAS simulation.
Carry out when: "Major" teach-in process "Minor" teach-in process
Exchange of a different transmission (e.g. G 210 replaced by G 240).
The transmission has been overhauled.
Operations have been carried out on the transmission.
GS components have been renewed on the transmission.
GS control unit has been renewed.
Replacement of a different engine (engine with higher or lower

power)
Transmission or engine has been removed and fitted.

Telligent Transmission II, Teach-in Process and Teach-in Faults GS II 173
GS teach-in faults
With the "minor" and "major" teach-in process in the GS system, various error messages can be displayed by the GS control unit on the screen of the instrument
cluster.
These error messages on the screen are teach-in and operating errors.
Task 2 m While the "minor" teach-in process is carried out, the message GS 24 appears in the display and the
teach-in process is aborted.
Which does this message mean?

Telligent Transmission II, Teach-in Process and Teach-in Faults GS II 174
Hydraulic-Pneumatic Transmission (HPS) Code GE3 02.09.2004
Design and arrangement of parts
5 Shift control
6 Gear cylindrical actuator
7 Gate cylindrical actuator
8 Compensation reservoir
W26.60-1080-06
On the HPS, the force of the gearshift lever generates a hydraulic pressure in the shift control. The pressure is delivered on to the corresponding shift cylinder
over a hydraulic line. The cylinder correspondingly shift to the gear or gate specified by the driver. The hydraulic transfer of the shift forces results in more
freedom in contrast to a mechanical circuit.

Hydraulic-Pneumatic Transmission (HPS) Code GE3 175
Function of the gear selection
The hydraulic pressure from the shift control is transferred to the gear cylindrical actuator over lines and hoses corresponding to the movement of the gearshift
lever.
Select direction
A even gear (2, 4 etc.)
C odd gear (R, 1, 3 etc.)
N neutral position
5 Shift control
6 Gearshift lever
W26.60-1072-05

Function of the gate shift
The hydraulic pressure from the shift control is transferred to the gate cylindrical actuator over lines and hoses corresponding to the movement of the gearshift
lever.
Select direction
B lower gear range

(R, 1-4)
D higher gear range

(5-8)
N Neutral
Shift control viewed from the rear
5 Shift control
7 Gate cylindrical actuator
W26.60-1075-05

Venting HPS
The shift cylinders are each fitted with a venting nipple and a venting screw. The axial bore connects the venting nipple with the venting screw. This allows both
hydraulic circuits to be vent from one venting nipple. The dust cap on the venting nipple prevents dirt getting in to the axial bore. For this reason, is must always
be fitted.
1 Venting nipple
2 Venting screw
6 Shift cylinder
6.6 Axial bore
6.7 O-ring seal
W26.60-1079-01
Task 1 m Determine the labor regulation for venting the HPS in WIS. Read the regulation and discuss any
uncertainties.

Transmission Practical 02.09.2004
With faults in the gear control, it is possible to activate the back-up mode from the multifunction steering wheel. In the back-up mode, the driver can drive the
vehicle to nearest workshop.
Task 1 m Activate the back-up mode using the operating instructions! Which shifts are possible in this mode?
Note down!
If the vehicle has to be towed away the towing mode can be activated using the multifunction steering wheel.
Further measures for towing are dealt with in the "Towing Regulations" chapter.
Task 2 m Activate the towing mode!
Task 3 m Carry out the minor teach-in process on the transmission.

Transmission Practical 179
Learn Targets <> Towing Regulations / Telligent LC / Telligent BS 02.09.2004
M
After this chapter you can . . .
Towing instructions:
q recognize the towing regulations and its effects.

q describe the procedure for towing after damage to the engine, transmission or rear axle.
Telligent LC:
q name the advantages of the LC.

q describe the special features the 2-bellow air suspension.
q explain the function of the LC.
q understand the function of the increased drive mode and the starting-off aid.
q activate the memory and the stand-by function from the operator panel.
q read out the axle load in the instrument cluster.
q calibrate the driving level.
Telligent BS
q explain the design and repair of the disc brake.

q name the advantages and the design of the Telligent brake system.
q assign the functions of the Telligent brake system tot he corresponding components.
q name the function of the differential slip control.
q carry out pressure tests on the brake system.
q carry out fault finding with DAS.

Learn Targets <> Towing Regulations / Telligent LC / Telligent BS 180
Towing Regulations 02.09.2004
Task 1 m In the towing regulations, differentiation is made according to the causes:

Use the operating instructions to do this!
Þ With engine damage, the towing distance must be taken into consideration!
Towing distance up to 1 km · Towing speed max. 10 km/h

· Shift transmission in neutral position. The vehicle may be towed a
maximum of 1 km when the propeller shaft is fitted.
Towing distance up to 100 km · Towing speed max. 40 km/h

· Shift transmission in neutral position.
· Unscrew the plug on the transmission housing (above the propeller
shaft). Screw in to the stop and tighten the "GP" adjustment bolt
(vehicle tool kit), only on HPS.
· On veh. with GS enable the "towing back-up mode".
Towing distance over 100 km · Towing speed over 40 km/h

· Remove the propeller shaft to the drive axle.
On vehicles with Telma-retarder, the propeller shaft to the drive axle must be removed.
If the specified speed or towing distance is exceeded the propeller shaft to the rear axle must be disconnected at the flange/removed.
Attention: For safety reasons, we recommend that generally the propeller shaft to the rear axle be disconnected at the flange when towing!

Towing Regulations 181
Towing with rear axle damage (HL7)
Task 2 m Using the operating instructions fill in the missing text in the gaps!
· With rear axle damage, the differential lock and both drive shafts
.
· On rear axles with , drain the oil.
· Dismount the end cover of the planetary hub reduction drive and remove the circlips.
· Remove the drive shaft with the special tool or with a .
· Fit the end cover again.
· On a towing distance fill the oil in the planetary hub reduction drive.
Fill text:
120 mm long M8 bolt removed over 100 km
is to be switched on planetary hub reduction drive

Towing Regulations 182
Telligent Level Control (LC): Advantages 02.09.2004
The advantages of the level control (LC) are:
· increased driving and transport comfort through lower vibration frequencies · decrease of the rolling resistance and of the wear through relief of the
leading or lift axle with a partially or entirely unloaded vehicle.
· high operating comfort through simple and clear arrangement of the
controls · increased transport volume through lower frame height
· easy operation on individual change of the frame height · faster damage recognition through extensive diagnosis capability
· faster coupling and uncoupling or setting down and pickup of swap bodies · lower compressed air consumption
· constant vehicle height with loaded and unloaded vehicle · possibility of displaying the individual axle loads and the total vehicle weight
in conjunction with the SE axle load measuring device
· simplification of the loading and unloading through faster adjustment to
different loading dock levels and constant frame height during the entire · integrated control and monitoring of the leading and trailing axle and the
loading process axle lift function

Telligent Level Control (LC): Advantages 183
Level Control (LC): Design 02.09.2004
W32.33-1119-79

Level Control (LC): Design 184
Legend:
1 Front lift/sink indicator lamps B51 Front axle position sensor

2 Rear lift/sink indicator lamp B52 Left drive axle position sensor
3 Front lift/sink on/off button B53 Right drive axle position sensor
4 Rear lift/sink on/off button S50 Control panel for level control
5 Frame height M1 button P2 Instrument cluster (INS)
6 Frame height M2 button P2p1 Driver information display
7 Drive setting button Y26 Front axle solenoid valve
8 Lift button Y27 Level regulation solenoid valve 2-axle vehicle
9 Sink button Y28 Level regulation solenoid valve 3-axle vehicle
10 Stop button CAN 1 Vehicle CAN
11.1 "Vehicle frame above normal position" symbol CAN 3 Frame CAN
11.2 "Vehicle frame below normal position" symbol
A7 Base Module (BM)
A64 Front module (FM)
A65 Rear module (RM)

Task 1 m Assign the specified functions to the corresponding components.
Functions Components
Accepts the wishes of the driver
Transmits the operator panel information on to the rear module
Passes the values of the position sensor on to the front axle
Vents and pressures the air bellows on the drive axle
Vents and pressures the air bellows on the front axle
Reads the values of the drive axle travel sensors
Lights up the vehicle frame too high or too low symbols
Is the function master of the LC

2-Bellow Air Suspension 02.09.2004
On the ACTROS MP II semitractor trailers 4x2, 6x2/2 and

6x2/4, a 2-bellows air suspension is fitted on the rear
axle instead of the 4-bellows air suspension.
The main changes are:

· Triangular control arm bolted directly to the bracket
fixed to the frame for the stabilizer link
· Shock absorber arranged behind the rear axle
· max. bellows pressure increased from 6.3 to 7.6 bar
· Tapering frame section over rear axle enlarged
The main advantages are:

· The arrangement of the shock absorber behind the
axle results in significant advantages with vehicle
dynamics and roll behavior
· The extremely advantageous arrangement of the air
spring bellows allow significant larger lift height and
prevents a twisting of the rear axle and an
accompanying change in the propeller shaft angle
· Weight reduction by approx. 30 kg
· Frame height in comparison to the previous ACTROS N32.00-2023-50

lowered by 30 mm

2-Bellow Air Suspension 187
Increased drive mode on vehicles for large-volume transport
It is possible to raise the frame in driving mode on rough road conditions to the improve the suspension comfort.
Raise frame: Push the switch upwards. The multifunction display shows the raised drive mode.
Lower frame: Push the switch downwards. The display goes out when the drive position is reached.
In the driving mode, the permissible vehicle height may not exceeded in the raised drive position.
1 raised drive position switch

Starting-off aid
The starting-off aid is a legally permissible traction aid, where the axle load on the drive axle may be exceeded by a set value (in Germany by 30%). In Germany
the starting-off aid switches off at a speed of >30 km/h. Other regulations may be applicable in other countries.
1 starting-off aid switch 2 starting-off aid / trailing axle display 3 starting-off aid / leading axle display
After pressing the starting-off aid switch, the carrying bellows of the leading or trailing axle are vented and the lift bellows pressured. The carrying bellows of the
drive axle are pressured to maintain the driving level. To do this, the rear module makes sure that the permissible drive axle load is not exceeded using both
pressure sensors (B54 B55) on the drive axle. The switch on of the starting-off aid is shown to the driver by the flashing of the corresponding display in the
instrument cluster.

LC Operator Module Practical 02.09.2004
Various functions can be carried out with the operator module for practical use. The "lift and sink" functions are only possible up to a speed of 30 km/h.
1 front lift/sink indicator lamp

2 rear lift/sink indicator lamp
3 front lift/sink on/off button
4 rear lift/sink on/off button
5 frame height reservoir button M1
6 frame height reservoir button M2
7 drive position button
8 lift button
9 sink button
10 stop button (lift/sink)
W32.33-1124-12

LC Operator Module Practical 190
Task 1 m Save a frame height on both 5 and 6 buttons. Use the operating instructions. Make notes keywords on
how you proceeded.
Task 2 m Set the vehicle frame to any height and activate the stand-by circuit. Note down the time period over
which the circuit is active.

LC Operator Module Practical 191
Axle Load Display Practical 02.09.2004
Axle Load Display (SE)
On vehicles with Telligent level control (LC), the axle load of the air suspended axles can be requested.
The display of the current axle load gives information to the driver. It is not a calibrated system and
cannot be calibrated. For this reason, the information cannot be used for official purposes.
To prevent erroneous displays with the display of the axle load, the vehicle must be brought in the normal
position using the level regulation operator module (lifting and lowering again). Switch off the starting-off
aid and read off the displayed value.
With partial air suspension, the information for the front axle and the gross weight are not displayed.
The display can be readjusted (see operating instructions).
Task 1 m Determine the axle load on the vehicles available to you.
Front axle: 2nd axle: 3rd axle:

Axle Load Display Practical 192
Driving Level Calibration Practical
Task 2 m Calibrate the vehicle level on the training vehicle.

Name the height of the spacer on the rear axle and the required U-pieces of the front axle.
W32.22-1008-01 W32.22-1007-01

Axle Load Display Practical 193
Disc Brake 02.09.2004
Disc brakes have been used for many years also in the commercial vehicle
sector.
Vehicles for local and long-distance traffic have disc brakes on all axles. Dumper
and construction site vehicles, on the other hand, are delivered with drum and
disc brakes or only drum brakes.
The reason is the high danger of soiling.
In the ACTROS disc brakes from the Knorr company of the model SB 7000 are
used.
The advantages of this brake type are as follows:

· A high amount of same parts due to the modular system, thus advantages
with spare part supply
· A higher efficiency due to less moving parts and low-friction bearings
· Good brake power distribution through "two-plunger" brake actuation
· Integrated automatic adjustment, working synchronously on both actuation
plungers
· Directly flange-mounted brake cylinders, disposing of brake shaft, external
levers and adjustment mechanism
· Low air consumption through the use of normal-stroke diaphragm cylinders
· Compact construction
· Continuous wear monitoring through a brake-integrated sensor
· High lining and disc life
· Easy to service
W42.10-1015-82

Disc Brake 194
Function of the disc brake
Brake operation:
During braking, the brake cylinder (7) pushes on the eccentrically mounted
lever (6) with the force F1. The force F1 is translated by the lever ratio and the
eccentric bearing of the lever (6). It works with the force F2 on the inside
brake pad (4) via the bridge (5) and integrated threaded tube with thrust
pieces (9). After overcoming the air play, the inside brake pad presses against
the brake disc and the reaction force F3 now working via the disc caliper
pushes the outside brake pad (2) against the brake disc with little force F2.
Release of the brakes:
After release of the brake pressure in the brake cylinder (7), both push springs
(8) with integrated threaded tube, thrust pieces (9) and lever (6) push the
bridge (5) back to the starting position back.
Note:
No work operations are permissible on the tensioners and the automatic

brake wear adjustment. For this reason, in a complaint case, the tensioner
assemblies must be completely exchanged.
W42.10-0014-11

Disc Brake 195
Brake caliper repairs
Watch the video about the removal and fitting of the disc brake pads and the repair of the brake caliper.
Then solve the following tasks!
Task 1 m Specify the sequence when replace the disc brake pads.
1 Brakes released, test play 0.6 - 1.1 mm (between lining and thrust piece)
1 Fit brake pads, make basic setting, operate brakes repeatedly.
1 Brake test on roller dynamometer.
1 Remove brake pads, test sealing elements and disc caliper repair if necessary.
1 Turn back the adjuster, test the adjustment with stuck-on box wrench.

Disc Brake 196
Task 2 m In the illustration, mark the replaceable parts.
W42.10-0020-09
1 Brake caliper 4 Fixed bearing brass bushing 7 Floating bearing guide sleeve
2 Bellows fixed bearing circlip 5 Fixed bearing guide sleeve 8 Adjuster
3 Bellows fixed bearing 6 Floating bearing guide sleeve s
Disc Brake 197
Testing the service limit of the brake discs and brake linings
Test the wear of the brake disc:

The wear of the brake disc and the one-sided wear can be determined on the chamfer
(distance C)!
Note:
If the chamfer is no longer visible or worn on one side or the wear size has been reached the
brake disc is to be replaced.
Task 3 m Determine the dimensions for the brake discs listed in the
table. Enter the values. You can find the values in WIS
under AR42.10-W-0120A.
Size in mm
New brake disc
Service limit
Repair size
Wear thickness per side 4 mm
W82.10-0008-02
1 Brake disc
Task 4 m Assessment notes for the brake discs are stored in WIS. Write A New disc total thickness
down the document no.! B Service limit
C Chamfer = wear thickness of
- brake disc per side
>
Disc Brake 198
Telligent Brake System BS 02.09.2004
Advantages:
Shortening of the brake distance by reducing the response and Easy brake actuation, passenger car-similar pedal feel through . . .
pressure buildup through . . . · Electropneumatic actuation
· Electropneumatic actuation · Shorter pneumatic cables
· Shorter pneumatic cables · Larger valve cross-section
· Larger valve cross-section · Large dimensioned disc brakes
· 10 bar constant pressure system · Operation of a brake power sensor from the brake pedal
· Large dimensioned disc brakes
· Operation of a brake power sensor from the brake pedal
· Better brake power distribution under the axles
Higher idle time of the wheel brake through . . . Extended diagnosis and service possibilities through . . .
· Large dimensioned disc brakes · Permanent self-testing and monitoring of all main components and
· Better adjustment of the participation of the trailer in braking of functions with a start test cycle, triggered on each start.
the entire tractor/trailer combination · The drive test cycle is also active during operation.
· Wear-dependent adjustment of the brake power distribution under · Display of possible system malfunctions by the on-board display
the vehicle axles · Read out of measured values from the on-board display in the
workshop test cycle
Improved brake power distribution between engine vehicle and trailer · Display of actual measured values and fault codes in plain text
through . . . from the diagnostic interface using a diagnosis device
· Electropneumatic actuation · Direct activation of particular parts with HHT
· Better adjustment of the participation of the trailer in braking of
the entire tractor/trailer combination
· Automatic brake power distribution between tractor vehicle and
trailer

Telligent Brake System BS 199
Design of the Telligent brake system
5.01 Single-chamber comp. air reservoir

12.07 Brake wear sensor
12.08 Rpm sensor
13.07 Brake value sensor
16.07 Proportioning relay valve
18.07 Trailer control valve
20.02 Single-circuit diaphragm cylinder
22.01 Combination cylinder
30.08 FA redundancy valve
31.08 Axle modulator for drive axle
33.10 RA redundancy valve
35.02 Coupling head supply
35.03 Brake coupling head
45.01 ABS solenoid control valve
A11 BS control unit
X12 Trailer socket
N42.25-2049-06
n
Task 1 m Assign the specified functions to the corresponding components.
Functions Components
Controls and monitors all processes in the BS -
Passes on the driver's deceleration wish on to the BS control unit -
Controls the brake pressure for the front axle -
Controls the brake pressure on the rear axle -
Is responsible for the trailer control -
Retains the pneumatic pressure from the brake value sensor on the front axle with an -
intact system
Reports the wheel speeds to the control unit -
In a redundancy case, passes on max. half of the reservoir pressure to the rear axle. -

Front Axle/Rear Axle Control Loops 02.09.2004
a m/s2
a m/s2
Air pressure V2
Prop. relay
valve s Brake value
s sensor
Air pressure V1
n
Braking effect
Braking effect
n
Front axle Rear axle
n
Front Axle/Rear Axle Control Loops 202
Trailer Control Control Loop 02.09.2004
t (%)
a m/s 2
V3 Trailer
control
valve
n
FA RA
pm (bar)

Trailer Control Control Loop 203
Pneumatic Function Plans 02.09.2004
To find the relevant parts in the pneumatic plans, the plans also have a coordinate system, the same as the circuit diagrams.
Display of the brake units takes place when nothing else is noted in drive position (brakes not actuated).
Compressed air lines that are, for drawing reasons, shown interrupted in the
function diagrams are marked as the adjacent: BB / 13 . 05 . 12
Part location in the function diagram
Connection designation on component
Component, to which the air line leads.
Assembly
Lines are shown differently according to their functions.
Colors and types of lines:

Red = Reservoir pressure
Red = Control pressure (reservoir pressure)
Yellow = Brake pressure
Yellow = Control pressure (brake pressure)

Pneumatic Function Plans 204
Blue = Air spring bellows pressure
Blue = Control pressure (air spring bellows

pressure)
Black = Electrical line

The marking of the connectors on the air pressure valves consists of a one or two-digit number. The meaning of the first digit is:
0 Intake connection 6 Electrical connection

1 Energy input 7 Antifreeze connection
2 Energy output 8 Lubricant connection
3 Atmosphere connection (ventilation) 9 Coolant connection
5 Reserved
A second digit is intended for when several similar connectors are present.
Task 1 m Complete the table. Use the Actros 4X2 brakes function diagram to do this.
Coordinates of the part 6.12 -

Designation of the part 6.12 -
Function group of the part 6.12 -
Connection designation of the part 6.12 -
Which further parts are also located in the PG -
function group?

Telligent Brake System (BS) - Redundancy 02.09.2004
When the brakes are operated, the pressure is set by the brake value sensor on the connections 21 and 22.
On an intact BS, this pressure arrives at the wheel cylinders of the front and rear axles.
GT42_10_0006_C71
Task 1 m Find out, using the functional plan, which valves on an intact BS hold back pressure on the FA and RA
that is set by the brake value sensor.
How are the valves actuated?
Valve designation Actuation
Front axle
Rear axle

Telligent Brake System (BS) - Redundancy 207
Semitrailer Tractor Pressure Limitation 02.09.2004
To prevent overbraking of the front axle in redundancy operation, it may be braked with the entire pressure.
This is ensured by a pressure limitation.
Task 1 m Cross the right statements about the pressure limitation!

Use the brake systems function diagram to help you!
a The pressure limiting valve has the designation 30.03.

b The pressure limiting valve limits the outgoing brake pressure on the brake value
sensor connection 21 .
c The pressure limiting valve limits the incoming reservoir pressure on the brake value
sensor connection 12 .
d The pressure limiting valve limits the pressure to 3.5 +0.3 bar.
GT42_10_0005_C71 Pressure limiting valve

Semitrailer Tractor Pressure Limitation 208
Semitrailer Tractor Auxiliary Brake Valve 02.09.2004
General:
The effect of the auxiliary brake is placed on the brake circuits of
the front and rear axles.
On failure of the compressed air in the front axle circuit, the traction
on the rear axle is not enough for a sufficient auxiliary brake effect
in solo operation (without semitrailer the RA is too light), so that
here an aiding measure has been used.
W42.25-1058-01

Semitrailer Tractor Auxiliary Brake Valve 209
Task 1 m Find out, which measure is used here.
Cross it!
a Both front wheels brake with pressure from the reservoir circuit 4.
b Only the right front wheel brakes with pressure from the reservoir circuit 4.
c Only the left front wheel brakes with pressure from the reservoir circuit 4.
General:
The auxiliary brake valve function can be read out by the ingoing and outgoing
pressure in the diagram.
1 Characteristic of the auxiliary brake valve
N42.25-2020-11

Semitrailer Tractor Auxiliary Brake Valve 210
6 x 2 Brake Pressure Control on the Trailing Axle 02.09.2004
The brakes on the trailing axle receive the same pressure from the axle modulator as the drive axle.
In the case of an ASR differential lock brake control the trailing axle may not also be braked. For this purpose, there are two double check valves 28.04 and a
3/2 directional control valve 33.08 fitted to trailing axle.
Task 1 m How is it prevented that the trailing axle is also braked in an ASR case? Make brief statements. Use
the corresponding braking plan.

6 x 2 Brake Pressure Control on the Trailing Axle 211
Brake System Practical 02.09.2004
An operation frequently carried out in the workshop is the external filling of the compressed air system. This work is described in the WIS document
AR42.60-W-0070A.
Task 1 m Opening the document in WIS and read the operation regulation. Now look at connection point named
in WIS on the vehicle and note down the connection designation on the air drier.
Task 2 m In the WIS document AR42.60-W-0020A Pressure Controller-Testing Cutoff Pressure, determine the
specified values. Subsequently, carry out the pressure controller test. Enter the values.
Specified Actual
Pressure controller cutoff pressure in bar
Pressure controller switch range in bar
The ACTROS brake system is a 10 bar constant pressure system, which has a constant pressure reservoir in series to the brake circuits 1 and 2 with 12.3 bar. The
circuits 3 and 4 work with a limited pressure of 8.5 bar. The pressure limiters are fitted in the four-circuit protection valve.

Brake System Practical 212
Task 3 m Test the pressure limiter in the four-circuit protection valve and compare the measured values with
the bar display in the instrument cluster. Enter the values. Notes can be found in the WIS document
AR42.60-W-0040A.
Specified Actual Instrument cluster display

Circuit 1 operating pressure in bar
Circuit 2 operating pressure in bar
Circuit 3 and 4 operating pressure
in bar
BS fault finding
Task 4 m Read out the fault code and error text in BS using DAS. Then remedy the fault. Use the guided fault
finding in DAS to do this. Note down the fault code, error text and your procedure during the fault
remedy.
Fault code -
Fault text -

After the elimination of a fault or the renewal of parts in BS, a function test should always be carried subsequently to the work. This test is carried out in DAS
under the actuations menu.
Task 5 m Carry out the function test on the right ABS solenoid valve.
With certain dynamic faults, the driver is shown the illustrated event message (fault memory
bit). This display separately reset with DAS.
Task 6 m Reset the fault memory bit!

» ... Die Mitarbeiter werden zukünftig in die Rolle persönlicher Wissensmanager hineinwachsen
müssen, die aktiv die Verantwortung für ihre Qualifizierung übernehmen ... « Jürgen E. Schrempp
» ... Staff must in future assume the role of personal knowledge managers, who actively take
responsibility for their own qualification ... « Jürgen E. Schrempp
123456789
!"§$%&
DaimlerChrysler AG
Global Training
HPC T301
D-70546 Stuttgart
Intranet: http://intra-gt.daimlerchrysler.com
1511 1286 02 2. Edition 01.04 222

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Truck•Complete Vehicle <> ACTROS •

Models 930-934 • Basic Training

Printed in Germany Note:

1511 1286 02 - 2. Edition 01.04 222 As at 01/04

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

“ACTROS , the new truck experience”

is the motto, under which the new ACTROS BM 930-934 is presented

The foreground of the vehicle development was to bring a reliable

The requirements of a modern truck are constantly increasing.

Furthermore, the ACTROS shows the development and

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

1st day 2nd day 3rd day 4th day

· Greeting · Instrument cluster · Engine · Telligent level regulation

· Vehicle networking · Modular switch panel · Steering · Brake system

· Base module · Exterior Lighting · Clutch · Final test

· Trailer Socket · Modular switch panel · Transmission

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

After the working through this section you can...

Vehicle visual inspection:

· name the model designation of the Actros model refinement

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

Transmission/chassis 3 2 Cab outside

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

Lane assistant Diagnostic socket

Base module with

Bunks Modular switch panel

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

Model plate Front cab mounting

Maintenance flap lock Stowage compartments

Autonomous intelligent Headlamps

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

W32.33-0024-01 GT42_10_0007_C71 W54.21-1218-11 W32.33-0025-01 Battery holder W31.00-1023-71

FA redundancy valve Power Distributor

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

ACTROS ACTROS MPII Engine Vehicle version

950 930 OM 501 LA, OM 502 LA Flat-bed vehicles

Vehicle model plate (example)

Please find further information in WIS (GF00.10-W-0025-02P).

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

The ACTROS driver cabs

To meet the usage requirement of the various

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

· 3-piece plastic bumper (steel on · Decreased side windows and mirror

· Large-volume stowage compartments · Reduction spray formation through

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

· Stowage compartment accessible from inside and outside

· Megaspace total storage space approx. 475 l

GT68_00_0022_C71 GT68_00_0023_C71 GT68_00_0024_C71

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

After the working through this section you can...

· understand the power supply on the electric modules

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training

Overview of the power supply on a vehicle with integral rear end

09/04 Truck•Complete Vehicle <> ACTROS • Models 930-934 • Basic Training