Mercedes-Benz 963 2022 Series Page 5 Manual Download

Page: 5 / 88

General

Preface

Safety and liability information

Vehicle identification

Hydraulic Auxiliary Drive (HAD)

Electrics/electronics

Battery box

Jump start

Battery disconnect switch

Electrical fuse

Tilting the cab

Cab tilt system

Before tilting the cab

Mechanical-hydraulic cab tilt system

Electrohydraulic cab tilt system

Starting/stopping the engine with the cab tilted

General operations/modifications

Vehicles with fuel prefilter

Vehicles without fuel prefilter

Shut off natural gas system

Transmission

Overview of gearshift

Mercedes PowerShift emergency operation mode

Transmission emergency shift mode with manual gearshift...

Live power take-off (NMV) emergency shift mode

Notes on turbo-retarder clutch

Compressed-air system

Actros, Antos and Arocs | Towing and recovery

Summary of Contents for 963 2022 Series

Page 1: ...Actros Antos and Arocs Towing and recovery Model series 963 964...

Page 2: ......

Page 3: ...Actros Antos and Arocs Towing and recovery Mercedes Benz Service Daimler Truck AG TE SCT...

Page 4: ...text images graphics audio files video files and animation files as well as their arrangement are all subject to copyright and other intellectual property protection laws These objects may not be cop...

Page 5: ...cab 28 Mechanical hydraulic cab tilt system 29 Electrohydraulic cab tilt system 30 Starting stopping the engine with the cab tilted 32 General operations modifications 33 Vehicles with fuel prefilter...

Page 6: ...59 Maximum permissible tractive forces 61 Towing 62 Towing general 62 Determine damage location with blocked drivetrain 65 Engine transmission and or axle damage 66 Propeller shaft removal 67 Drive sh...

Page 7: ...display Warning note Note Warning Warning Environmental note Environmental note Environmental note Possible vehicle damage i Potential damage Instruction for action Procedural instruction All of the...

Page 8: ...ondition and checked for damage at a qualified workshop which possesses all the expertise and tools required to properly perform the necessary work You must observe the notes in chapter Recovery Note...

Page 9: ...Truck AG 2 EC operating permit number only for certain countries 3 Vehicle identification number VIN 4 Permissible gross mass kg permissible gross combination mass kg 5 Permissible axle loads of axles...

Page 10: ...h the electronic ignition lock to position 3 and start the engine If the key 3 is inserted and you press the start stop button 1 up to the 1st switching threshold you switch the electronic ignition lo...

Page 11: ...ch 5 Hazard warning system switch 9 Signaling horn 2 Instrument cluster 6 Fuse box 10 Multifunction steering wheel adjuster 3 Multifunction steering wheel 7 Parking brake 11 Left multifunction control...

Page 12: ...de J6B Multimedia Cockpit or code J6C Multimedia Cockpit interactive is available as standard equipment in vehicles with L cab and as special equipment in vehicles with S M cab The previous cockpit co...

Page 13: ...th USB connector Code J2B CD radio Bluetooth Code J2H Multimedia touch radio The Multimedia Radio Touch is available in combination with code J2G Digital radio with a digital receiver for the receptio...

Page 14: ...t cluster control unit is integrated via the following bus systems in the networking User interface CAN CAN 17 Frame CAN CAN 3 W54 21 A011 75 Instrument panel 12 Actros Antos and Arocs Towing and reco...

Page 15: ...Multifunction display 3 Tachometer 4 AdBlue level 5 Total distance and trip distance 6 Clock and outside temperature indicator 7 Fuel level W54 30 A062 76 W54 30 A065 09 Instrument cluster Actros Anto...

Page 16: ...lfunction 26 Power supply malfunction 13 Diesel particulate filter malfunction 27 Service date due 14 Diesel particulate filter automatic regeneration 28 Leading axle raised W54 30 A066 08 29 Trailing...

Page 17: ...Direction indicator lamp 3 Warning indicator lamps in the tachometer 4 Warning indicator lamps in the AdBlue gauge 5 Warning indicator lamps below the multifunction display W54 30 A063 76 W54 30 A065...

Page 18: ...malfunction 26 Power supply malfunction 13 Diesel particulate filter malfunction 27 Service date due 14 Diesel particulate filter automatic regeneration 28 Leading axle raised W54 30 A066 08 29 Traili...

Page 19: ...F button If TC indicator lamp in instrument cluster lights up ASR is switched off Switching Stability Control Assist off on Stability Control Assist switch Actros W54 25 A069 71 Press Stability Contro...

Page 20: ...ake Assist OFF indicator lamp in instrument cluster lights up ABA is switched off Switching on Press up on Active Brake Assist OFF button for around 1 second If Active Brake Assist OFF indicator lamp...

Page 21: ...radiator grille 1 next to the Mercedes star Variant B There are release levers 2 under the side paneling above the headlamps To open variant A Push both release levers 2 outward in direction of arrow...

Page 22: ...tified by the integrated hydraulic motor and the hydraulic lines When the hydraulic auxiliary drive is intact the vehicle can be towed without restrictions Remedy measure if hydraulic auxiliary drive...

Page 23: ...rve the following Immediately rinse the battery acid off your skin thoroughly with plenty of clean water and seek medical attention without delay If you have got battery acid in your eyes immediately...

Page 24: ...10 A050 71 Cover Vehicle with integral rear end W54 10 A047 71 Remove Open latch 2 and remove cover 1 upward Mount Mount cover 1 Hook in latch 2 and close Battery box 22 Actros Antos and Arocs Towing...

Page 25: ...e protected against reverse polarity and that have a cross section of around 35 50 mm and insulated terminal clamps A discharged battery can freeze if the outside temperature has dropped below 10 In t...

Page 26: ...TIVE terminal of jumper cable onto positive terminal of booster battery first Push back red cover with POSITIVE terminal of jumper cable and clip onto positive terminal Clip NEGATIVE terminal of jumpe...

Page 27: ...onnect switch e g when loading a vehicle in a hazardous goods zone Only use the battery disconnect switch with the vehicle stationary Observe notes on event message in on board computer Switch the ele...

Page 28: ...ronic control units If there is a malfunction the electronic control unit switches the consumer off If an electric circuit fails switch off consumer and switch electronic ignition lock to position 0 S...

Page 29: ...ing range Only stand under the cab when it is in the fully tilted position i If you need to open a door when the cab is tilted it must be moved carefully and slowly to the end position The A pillar or...

Page 30: ...to the separate operator s manual for the refrigerator box Wait 10 minutes after tilting back the cab before switching the refrigerator box on again Remove loose objects from the cab or stow them sec...

Page 31: ...ver check the tilt position 2 at the valve lever of the tilt pump If no resistance can be felt on the pump lever have the tilting hydraulics checked at a qualified workshop W60 80 A009 71 Tilt cab bac...

Page 32: ...et louder the cab is at the forward end position Tilt cab back into driving position Press and hold the Tilt button on the remote control 1 until the cab is tilted back to the rear end position and lo...

Page 33: ...valve lever on tilt pump in cab to drive position 1 Press and hold the button 3 until the cab is tilted back to the rear end position The cab locks automatically Swing down flap on right at entryway...

Page 34: ...Tilt cab forward see Chapter Mechanical hydraulic cab tilt system or Electrohydraulic cab tilt system Starting the engine and increasing the engine speed External engine start stop button 1 W15 30 A00...

Page 35: ...uel emerges bubble free at vent screw 5 Tighten vent screw 5 If there was no fuel in the fuel tank press hand pump 4 again until a perceivable resistance is perceptible Also bleed with the hand pump a...

Page 36: ...rocedures Otherwise you can damage the starter i If you start the engine after bleeding Wait for 10 minutes are three starting attempts You could otherwise damage the starter Vehicles with fuel prefil...

Page 37: ...sistance is perceptible Within approx 5 seconds press external engine start stop button and start engine see Chapter Engine start shut off for a tilted cab Please note that you must start the engine w...

Page 38: ...tarting procedure is automatically interrupted after approx 60 seconds If the engine ignites regularly release start stop button 6 and depress accelerator pedal several times The fuel system will blee...

Page 39: ...explosion proof devices Take into account the blow out directions of the gas cylinders in vehicles that are located on the side or on the roof as controlled darting flames can occur when the thermal f...

Page 40: ...shutoff vehicle in gasoline operating mode and in the case of an accident the gas cylinders 1 are automatically locked by an electromagnetic shutoff valve The thermally activated safety valves with fu...

Page 41: ...p approx 200 up to 125 bar 1 2 half full p approx 124 up to 50 bar 0 fuel reserve indicator and empty p approx 49 up to 0 bar 1 Gas reservoir fill level indicator 2 AdBlue display nonfunctional A1 Ins...

Page 42: ...operation is controlled automatically by the transmission control Depending on the transmission mode the gears are selected either automatically by the transmission control or manually by the driver...

Page 43: ...fighting vehicles the transmission mode performance is activated when the engine is started 1 Allison 3000 PR 2 Pressure reservoir 3 Allison 3000 P W27 10 A000 76 Overview of drive programs Designati...

Page 44: ...eration Mode using up arrow or down arrow button The menu window shows Press OK to activate Press OK button The menu window shows Parking brake engaged Press right arrow button The input window shows...

Page 45: ...pter Manual hydraulic cab tilt system or Electrohydraulic cab tilt system If installed Remove soundproofing cover Remove cover 1 of gearshift shaft using a flat screwdriver Turn gearshift shaft to neu...

Page 46: ...cked at a qualified workshop Depending on the equipment installed the cab must be tilted to access the selector lever Switch electronic ignition lock to position 0 Apply parking brake Tilt cab if nece...

Page 47: ...r take off using a propeller shaft for the following systems Semitrailer trailer hydraulic systems Rear fan Coolant pump Leading axle steering If the propeller shaft fails the malfunctions described b...

Page 48: ...o position 3 in variant B Take off wrench and adapter Attach cover cap 1 Start engine Press top of power take off switch When the power take off is switched on the display of the on board computer sho...

Page 49: ...er take off N4Y or N4Z Vehicles with power take off variant A N4Y or N4Z Turn the wrench to position 3 If the power take off was previously automatically engaged via the switch in vehicles with power...

Page 50: ...a lower gear so that the oil temperature drops If the event message and warning tone do not go out Apply parking brake Shift transmission to neutral Let engine run at approx 1200 rpm for around 1 minu...

Page 51: ...driver s request to actuate release the parking brake via the parking brake lever control unit in the instrument panel For the electric parking brake the actuator relay valve and the control of the p...

Page 52: ...ing is realized by pulling releasing the parking brake lever the braking effect is in this connection proportional to the position of the parking brake lever Workshop mode The system can be switched i...

Page 53: ...he compressed air drier under the following conditions If you route the compressed air system via the test connections on the brake value sensor behind the maintenance flap If you fill the compressed...

Page 54: ...akes via the compressed air lines at test connections 21 and 22 on the brake value sensor This actuates the service brake of the vehicle to be towed i Depending on the brake value sensor installed the...

Page 55: ...stable pressure reducing valve pressure regulator for unladen or partially laden vehicles With this the rear axle brakes can be actuated according to the load condition Ensure power supply for lightin...

Page 56: ...ed using the test connections at the brake value sensor see chapter External filling of compressed air system i The reservoir pressure must not exceed 12 5 bar Releasing the spring brake cylinder mech...

Page 57: ...ed Secure vehicle with chocks to prevent it from rolling Turn release screw 2 of spring loaded brake cylinder 1 left up to end stop in release position 4 Restoring spring brake cylinders to driving po...

Page 58: ...aise lower the chassis In a laden vehicle pressures up to 8 5 bar are permissible In an unladen vehicle pressures of up to 8 5 bar on the front axle and up to 3 5 bar on the rear axle are permissible...

Page 59: ...xceeded the warning buzzer sounds Select a higher start off gear or reduce the towing speed Switch electronic ignition lock to drive position The indicator check runs If the indicator check does not r...

Page 60: ...an emergency If you are steering whilst towing a red event message will be displayed in the on board computer display Abort the tow starting procedure and stop the vehicle Switch the electronic igniti...

Page 61: ...recovering If possible unload the vehicle first especially vehicles with box bodies This reduces the towing forces required Further damage to the vehicle can be reduced to a minimum If it is not poss...

Page 62: ...nsverse control arms stabilizer bars including attaching parts Wheels Wheel hub tires rims wheel mounting parts Brake All controls and mechanical hydraulic pneumatic and electrical brake force transmi...

Page 63: ...ow rope 20 t tractive force with maximum 15 towing angle i It is not permissible to apply force to the crossmember in semitrailer trucks with a weight optimized crossmember Weight optimized crossmembe...

Page 64: ...st the ASR ESP ABA system may perform uncontrolled braking actions Switch the ASR ESP ABA off and disconnect the battery before towing the vehicle Note Trailer semitrailer with ABS When towing entire...

Page 65: ...ing i Further information on Towing raised section in chapter Towing raised Vehicle with electric power steering W46 25 A044 75 Rules for towing Remove propeller shaft to avoid damaging transmission s...

Page 66: ...es PowerShift Switch on towing mode for this purpose see chapter Emergency operation Mercedes PowerShift Secure vehicle to prevent it moving away Start the engine not if the front axle is raised Charg...

Page 67: ...er shafts 7 8 do not move Transfer case damage 3 The engine transmission block twists in the frame The propeller shafts 2 8 and 10 do also move slightly on vehicles with transfer case Rear axle damage...

Page 68: ...t the transmission or the transfer case does not turn when driving otherwise the transmission or the transfer case could be damaged Engine damage Remove propeller shafts to drive axles see chapter Pro...

Page 69: ...ear axle 6x6 Transfer case 1st rear axle Transfer case Front axle Transfer case Front axle Transfer case 1st rear axle 8x6 Transfer case 1st rear axle Transmission 2nd front axle or 1st front axle 2nd...

Page 70: ...special tools see chapter Tools and Accessories If the screw 3 cannot be completely screwed in Pull drive shaft out approx 100 mm and turn until screw 3 can be completely screwed in W35 40 A005 71 Re...

Page 71: ...rive shaft and reinstall Attach end covers 3 W35 30 A025 71 Filling the planetary hub reduction axle with oil i Add oil to planetary hub reduction drive if towing distance exceeds 100 km Unscrew oil f...

Page 72: ...and turn 90 to right The CAMLOCK bolt 4 noticeably engages Mount coupling bolt cover 1 and clip in Vehicles with large angle of approach departure Fold up step Towing eye L cab Actros L cab Actros W60...

Page 73: ...upling pin 1 Pull out coupling pin 1 Insert tow bar Press coupling pin 1 downward through eyelet of tow bar Hook retainer 2 into coupling pin 1 again W31 10 A022 71 Towing with the tow bar Actros Anto...

Page 74: ...between the semitrailer tractor and the semitrailer particularly when cornering and when starting to drive up steep slopes Towing i On lowliners and low frame vehicles it is recommended that the nois...

Page 75: ...c arm must be taken into account due to the roll angle of the lifting yoke Laden vehicles which are raised at the towing eyes may only be towed at low speed and without dynamic shock loads Depending o...

Page 76: ...r Maximum permissible tractive forces A second towing eye is required if you wish to raise the vehicle at the front These can be purchased from a Mercedes Benz Service Center see page 68 You can tow a...

Page 77: ...ght optimized front axle do not lift the front axle in the center Raising and towing by the wheels Air sprung front axle W00 60 A008 71 Secure vehicle with chocks to prevent it from rolling Raise the...

Page 78: ...vehicle is insufficient to lift both front axles tow vehicle to next unloading opportunity as follows Raise vehicle at first front axle Remove wheels of first front axle Vehicles with drum brake on f...

Page 79: ...trailer trucks with a weight optimized crossmember Weight optimized crossmember do not have a hole pattern for a trailer coupling are 3 5 mm thick and have a stamped in item number of A 960 312 29 35...

Page 80: ...quare wooden block if the vehicle is not loaded meaning without body or fully enclosed swap body If the vehicle is partially laden place a square wooden block between the longitudinal frame member and...

Page 81: ...at left and right and secure against slipping Raise rear axle with lift fork Secure rear axle on lifting device Four axle vehicles Detach wheels from second front axle and secure brake drums with whe...

Page 82: ...er Drive shafts removal Screw M18x1 5x80 For locking differential on rear axle see chapter Drive shafts removal Y shaped adapter for brake value sensor Part number A 004 997 42 89 1x external thread M...

Page 83: ...wheel hub covers available from specialist dealers Model Axle load Hole circle diameter Bolts Quantity Undercut HL2 6 2 t 156 mm M14x1 5 8 27 mm HL2 8 5 t 164 mm M14x1 5 8 27 mm HL4 11 t 156 mm M16x1...

Page 84: ...W58 50 A002 71 Item Designation Dimension 1 Spacing of drawbars 1170 mm Aids for recovery towing 82 Actros Antos and Arocs Towing and recovery Tools and accessories...

Page 85: ...onal des marchandises Dangereuses par Route European Agreement Concerning the International Carriage of Dangerous Goods by Road ASR Acceleration slip regulation EAPU Electronic Air Processing Unit ESP...

Page 86: ...Area for notes 84 Actros Antos and Arocs Towing and recovery...

Page 87: ......

Page 88: ...Daimler Truck AG TE SCT Order no nur online Germany...

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