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Mercedes-Benz Actros 963, Manuallines

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Mercedes-Benz Actros 963 Manuallines Download Page 19

18

Battery disconnect switch

Electr

ical sy

st

em

Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)

Removing the cover of the electronics compartment

 

M

Open latches 

;

 and remove cover 

:

.

Location of fuses

:

Module A32 (relays)

;

Base module (SCA)

(fuses, relays and diodes)

=

Module A31 (relays)

?

Modules A1 and A2 (fuses)

Summary of Contents for Actros 963

Page 1: ...Towing and Recovery Actros Antos Model 963 Arocs Model 964 Guidelines for Breakdown Services...

Page 2: ...Daimler AG GSP OR D 70546 Stuttgart Mercedes Benz Service Towing and Recovery Actros Antos Model 963 Arocs Model 964...

Page 3: ...ng the engine with the cab tilted 24 Bleeding the fuel system 25 Bleeding vehicles with fuel prefilter 25 Bleeding vehicles without fuel prefilter 26 Gearshift 28 Overview of transmissions 28 Mercedes...

Page 4: ...g forces 48 Towing 49 General information 49 Blocked drive train 53 Engine transmission and or axle damage 54 Propeller shaft removal 55 Drive shaft removal 56 Towing with a tow bar 58 Towing in raise...

Page 5: ...are left to the discretion of the user All of the data in this brochure correspond to the technical status as of the copy deadline in December 2015 and may therefore differ from the current production...

Page 6: ...difications to electronic components their soft ware or wiring can impair their functioning and or the functioning of other networked components Safety relevant systems in particular may also be affec...

Page 7: ...udinal frame member Information on the identification plate Vehicle manufacturer Daimler AG EC operating permit number only for certain countries Vehicle identification number VIN Permissible gross ve...

Page 8: ...nic ig nition lock to position 3 and start the engine When the key is inserted and you press the start stop button as far as the 1st switching threshold you switch the electronic ignition lock to the...

Page 9: ...t panel Actros Exterior lights switch Instrument cluster Multifunction steering wheel Right multifunction control lever A Hazard warning system switch B Electronics compartment cover C Parking brake D...

Page 10: ...railing axle centered Trailing axle steering angle difference Cargo liftgate open h Tire pressure monitor warning Tire pressure monitor Oil level too low hydraulic power steering D Yellow Auxiliary st...

Page 11: ...older engaged l Active Brake Assist 2 switched off Stability Control Assist control malfunction k Stability Control Assist switched off ASR acceleration skid control switched off control malfunction A...

Page 12: ...up ASR is switched off Switching Stability Control Assist off on M M Press button k When the indicator lamp k in the instrument cluster lights up Stability Control Assist and ESP are switched off Swi...

Page 13: ...ght beside the Mercedes star Variant B The release levers are located under the side panels above the headlamps M M Opening variant A Push both release levers outwards in direction of arrow M M Openin...

Page 14: ...llowing Immediately rinse the battery acid off your skin tho roughly with plenty of clean water and seek medical attention without delay If you have got battery acid in your eyes immediately flush the...

Page 15: ...rger batteries with power supply unit pull the mains plug before jump starting Only jump start from vehicles with a 24 V system Use jumper cables that are protected against reverse polarity and have a...

Page 16: ...of the jumper cable to the positive terminal of the booster battery first M M Push back the red cap with the positive terminal clamp of the jumper cable and clip it onto the positive terminal M M Clip...

Page 17: ...tery disconnect switches depending on their ADR classification Once the vehicle has been parked safely you can use the battery dis connect switches e g when loading a vehicle in a hazardous goods zone...

Page 18: ...t and injury Only replace defective fuses with the specified fuses of the correct amperage The individual circuits are protected by fuses or circuit brea kers Other circuits e g the lights are fused v...

Page 19: ...and Recovery Actros Antos Model 963 Arocs Model 964 Removing the cover of the electronics compartment M M Open latches and remove cover Location of fuses Module A32 relays Base module SCA fuses relays...

Page 20: ...ithin the tilting range of the cab Only tilt the cab when you are certain that nobody is standing in the tilting range Do not stand under the cab when it is in the tilted position If you need to open...

Page 21: ...lectronic ignition lock to the drive position M M Switch off auxiliary heater M M Switch off stationary air conditioning M M Switch off refrigerator box Refer to the separate operating instructions fo...

Page 22: ...e cab is tilted to the forward end position M M If strong resistance can be felt on the pump lever check the tilt position 2 at the valve lever of the tilt pump M M If no resistance can be felt on the...

Page 23: ...b M M Press and hold the button of the remote control until the cab is tilted to the forward end position When the pump noise starts to get louder the cab is at the forward end position Tilting the ca...

Page 24: ...When the pump noise starts to get louder the cab is at the forward end position Tilting the cab back to the driving position with the button on the cab tilt pump M M Move valve lever on cab tilt pump...

Page 25: ...gine Leave the engine to cool down if possible Starting the engine and increasing the engine speed M M Hold down the external engine start stop button until the engine starts The engine runs at idle s...

Page 26: ...rew A free of bubbles M M Tighten the bleed screw A If there was no fuel in the fuel tank press the hand pump again until a noticeable resistance can be felt M M Also bleed with the hand pump at the e...

Page 27: ...ve position M M Tilt cab forwards see page 22 M M Open the cap of the fuel tank M M Unscrew bolts M M Remove cover M M Press handle on hand pump about 250 times within about 3 minutes until a noticeab...

Page 28: ...th engine OM 936 with the starter M M Apply parking brake M M Shift transmission to neutral M M Press start stop button all the way down and hold Do not depress the accelerator pedal The start attempt...

Page 29: ...4 reverse gears The clutch operation is controlled automatically by the trans mission control Depending on the transmission mode the gears are selected either automatically by the transmission contro...

Page 30: ...damage when you are towing the vehicle over a short distance with the propeller shaft installed Only use towing mode to tow the vehicle away from a danger area When you have towed the vehicle away fr...

Page 31: ...gearshift is inoperative and an engaged gear is preventing the vehicle from moving you can shift the Mercedes PowerShift transmission to the neutral position Depending on the vehicle equipment it may...

Page 32: ...engage 3rd 4th or re verse gear manually at the transmission You can move off in 4th gear It is not possible to change gear while driving Have the gearshift checked at a qualified workshop Depending...

Page 33: ...trucks Depending on the vehicle equipment installed the trans mission driven power take off uses a propeller shaft to drive hydraulic pumps for the following systems Semitrailer trailer hydraulic sys...

Page 34: ...ve cap M M Fit adapter with wrench at position 2 on the shaft M M Turn wrench to position 4 on variant A or to position 3 on variant B M M Take off wrench and adapter M M Fit cap M M Start engine M M...

Page 35: ...tified by the external clutch actuator If there is a cover panel here the vehicle is equipped with power take off N4Y or N4Z M M Vehicles with power take off variant A N4Y or N4Z Turn wrench to positi...

Page 36: ...drive special equipment is located at the wheel hubs on the front axle and can be identified by the integrated hydraulic motor and the hydraulic lines When the hydraulic auxiliary drive is intact the...

Page 37: ...n event window is displayed and an acoustic warning sounds M M Shift to a lower gear so that the oil temperature drops If the event window and the acoustic warning do not stop M M Apply parking brake...

Page 38: ...llowing components Pressure regulator Compressed air drier Multiple circuit protection valve Pressure limiting valve Control unit M M Secure vehicle using wheel chocks to prevent it from rolling away...

Page 39: ...r system via the test connection 28 on the EAPU Fill the pressure circuits to max 12 5 bar Otherwise components of the compressed air system could be damaged At the test connections on the brake value...

Page 40: ...lines M M Connect Y shaped adapter with compressed air line to brake coupling head of towing vehicle For further information on the adapter for the test connec tion see page 68 If the vehicle is unla...

Page 41: ...operating the vehicle again the spring brake cylinders must be returned to the driving position If the compressed air supply is insufficient the spring loaded parking brake can be released pneumatica...

Page 42: ...just 3 to 4 turns of unscrewing The appearance of the release indicator does not mean that the spring brake cylin der is already completely released Release all the spring brake cylinders on the vehi...

Page 43: ...M M If possible fill via test connection 28 on the EAPU and adjust the level via the operating unit Raising and lowering without an operating unit If the air suspension operating unit fails you can u...

Page 44: ...nt chassis frame height M M Raise lower the chassis frame to the required height M M Press and hold down button T M M Remove the key from the key slot M M Release button T If the reservoir pressure in...

Page 45: ...ith the batteries connected WARNING When tow starting the permanent brake engine brake retarder in the vehicle may perform uncontrol led braking actions Switch off the permanent brake before tow start...

Page 46: ...speed transmission Shift to 8th gear The engaged gear must be shown in the display of the onboard computer M M Tow start vehicle M M At about 10 km h slowly depress accelerator pedal The electronic sy...

Page 47: ...s to be exercised when applying external forces to the axles and axle connecting components When pulling in the longitudinal direction always use a towing crossmember and a 2nd towing eye if possible...

Page 48: ...ear axle s Rear axle beam and attaching parts for suspension and brakes Rear axle beam with steering elements Axle suspension Springs spring shackles spring bracket Air suspension bellows detachable p...

Page 49: ...max 15 towing angle Recovering by the coupling jaw using a suitable tow bar or a suitable tow rope 20 t pulling force no angle permissible Any application of force in the end crossmember is not permi...

Page 50: ...ing vehicle Fill the compressed air system from an external compressed air source If the oil pump in the transmission is inoperative transmission damage will occur when the vehicle is towed Before sta...

Page 51: ...covery vehicle When the engine is not running the oil pump in the transmission is inoperative If you tow the vehicle on one or more drive axles with the propeller shaft installed the transmission coul...

Page 52: ...uit and a hydraulic steering circuit Vehicle with electric steering assist WARNING When towing with a tow bar the electric steering assist function is activated at a speed of 9 km h At speeds below 9...

Page 53: ...he trailer semitrailer with an ABS cable 5 pin or 7 pin Make sure that the vehicle to be towed has all the requi red lights operating If you are towing the vehicle raised at the rear axle fold in and...

Page 54: ...ssion block twists in the frame Propeller shaft moves Propeller shafts and D do not move Transfer case damage The engine transmission block twists in the frame In vehicles with transfer case the pro p...

Page 55: ...n the sliding piece beforehand If this is not done there may be imbalance in the propeller shaft when it is reinstalled Make sure that the transmission or the transfer case does not turn when driving...

Page 56: ...rear 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 axle1 or 1st front axle...

Page 57: ...screw sensor using box wrench size 27 mm M M Carefully screw bolt all the way into shift cylinder housing M18x1 5x80 Special tools see page 68 M M If it is not possible to screw in the bolt Pull out d...

Page 58: ...gear To do this use special tool or a 120 mm long M8 bolt M M Detach sun gear from drive shaft and reinstall in axle gear M M Attach end cover Filling the planetary hub reduction axle with oil If the...

Page 59: ...coupling pin cover to the front M M Grip license plate bracket at side and swivel downwards M M Turn CAMLOCK bolt 90 to the left and remove M M Swivel coupling pin forwards by approx 90 and pull out...

Page 60: ...ad using an M45 x 3 tap M M Remove protective cap on front crossmember M M Screw towing eye all the way into front crossmember and turn to vertical position M M Pull out locking pin and take out pin u...

Page 61: ...clearance between the semitrailer tractor and the semitrailer particularly when cornering and when starting to drive up steep slopes Towing On Lowliner and low frame vehicles in particular and when us...

Page 62: ...yoke width extension may be neces sary to accommodate the drawbars see page 69 Use only drawbars that have been approved by Mercedes Benz The drawbars could otherwise be damaged Raising by the towing...

Page 63: ...k absorber bracket Shock absorber Steering arm Raising by the front axle M M Lift the front axle with lifting forks Ensure that the steering linkage springs stabilizer bars hoses and cables are not da...

Page 64: ...Pay attention to tie rods soundproofing panels and the level control system M M Set the lift fork to the track width of the vehicle It is recommended to remove the soundproofing see page 60 Damage co...

Page 65: ...ficient to lift both front axles tow the vehicle to the nearest unloading sta tion as follows M M Raise vehicle at first front axle M M Remove wheels of first front axle M M Vehicles with drum brakes...

Page 66: ...tractor uncoupled can be raised by the joints of the rear axle control arms and lowered onto wooden blocks so that it can then be pi cked up again Any application of force in the end crossmember is n...

Page 67: ...olumn to the vertical position M M Secure the steering wheel tangentially with 4 straps attached to the door grab handles Fit the straps tightly but do not stretch them Make sure that the switch panel...

Page 68: ...k between the longitudinal frame member and the lift axle M M Secure the vehicle to the lifting device with chains Attach the chains so that lines cables hoses and other detachable parts are not damag...

Page 69: ...hub reduction drive see page 56 Bolts Bolt M8x120 For extracting the drive shafts on axles with planetary hub reduction drive see page 56 Bolt M18x1 5x80 For locking the differential on the rear axle...

Page 70: ...sary because of the protruding axle tube otherwise the cover will not lie flat Other wheel hub covers available from specialist dealers Model Axle load Hole circle diameter Bolts Number Undercut1 HL2...

Page 71: ...ABS Anti lock braking system ADR Accord europ en relatif au transport international des mar chandises Dangereuses par Route European Agreement Concerning the International Carriage of Dangerous Goods...

Page 72: ...46 54 ESP Electronic Stability Program 44 49 60 F Filling pressure 40 Fluid coupling 36 Force application points 46 Frame distortion 46 Frame load 46 Front axle 42 47 52 54 60 61 62 63 64 67 Fuel pref...

Page 73: ...abilizer bars 47 62 Starting assistance 14 Straightening 46 Straps 46 66 T Test connection 38 42 68 Tilt pump 21 Tilting the cab 30 31 Towing angle 46 48 Towing options 61 65 Towing straps 46 Tow star...

Page 74: ...estions concerning this pro duct please write to us E mail customer support daimler com 2016 by Daimler AG This document including all its parts is protected by copyright Any further processing or use...

Page 75: ...Space for your notes...

Page 76: ...Daimler AG GSP OR HPC R 822 D 70546 Stuttgart 01 2016...

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