Mercedes-Benz Atego Manual Download

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Towing - Recovery
Atego

Daimler AG, GSP/OI, HPC R 822, D-70546 Stuttgart
Technical status 10/2008

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Summary of Contents for Atego

Page 1: ...Towing Recovery Atego Daimler AG GSP OI HPC R 822 D 70546 Stuttgart Technical status 10 2008 Towing Recovery...

Page 2: ......

Page 3: ...Service Daimler AG Teile Technik und Technische Information GSP TID D 70546 Stuttgart Towing Recovery Atego Guidelines for Breakdown Services 2009 Edition...

Page 4: ...ights reserved by Daimler AG If you have any questions or suggestions concerning this product please write to us at E mail customer support daimler com Fax 49 0 18 05 0 12 79 78 or Address Daimler AG...

Page 5: ...Plus onboard computer 20 Display messages 27 STOP lamp 29 Symbol and text messages 30 System abbreviations 42 Indicator lamps 43 Warning buzzer 46 Oil level in engine 48 Oil level in automatic transm...

Page 6: ...ource 81 Releasing the spring loaded parking brake 82 Telligent level control 86 Diagram of Telligent level control 86 Raising lowering the chassis frame 88 Filling the air suspension system from an e...

Page 7: ...ents 5 Guidelines for Breakdown Services Subject to technical modifications i Recovery 118 General 118 Maximum permissible pulling forces 119 Safety components 120 Special tools 121 Recovery Special t...

Page 8: ...recovered from a breakdown must be examined for technical condition and checked for damage at a qualified workshop which possesses all the expertise and tools required to properly perform the necessar...

Page 9: ...s i Vehicle model designation Location of vehicle model plate vehicle identification number 12 24 12 Permissible gross vehicle weight in tonnes 24 Engine output in hp x 10 1 Model plate example 2 Vehi...

Page 10: ...icle manufacturer 970 213 Vehicle model designation see below 1 Steering 1 left hand drive vehicles 2 right hand drive vehicles K Code letter or code number of manufacturing plant 896063 Vehicle ident...

Page 11: ...cator Page 30 Display messages with red status indicator Page 36 System abbreviations Page 42 Indicator lamps Page 43 Warning buzzer Warning buzzer Page 46 Oil level in engine Calling up the engine oi...

Page 12: ...8 Frequent stop brake Page 79 Hill holder Page 80 Overview of compressed air reservoirs Page 81 Filling the compressed air system from an external source Page 81 Spring loaded parking brake Page 82 Re...

Page 13: ...a display in the speedometer total mileage 4 1 Status indicator see page 28 8 Fuel AdBlue level gauge see page 14 2 Display Vehicles with Standard onboard computer see page 16 Plus onboard computer s...

Page 14: ...can be shown in the display To do this call up menu Check Info Reservoir Pressure see page 25 Risk of accident G Leaks in the compressed air brake system put the operational safety of the vehicle at r...

Page 15: ...modifications i Gear indicator Telligent automatic gearshift system The display shows the engaged gear 1 and the recommended or preselected gear 2 Standard onboard computer Plus onboard computer 1 En...

Page 16: ...segments in the Instrument If the AdBlue reservoir is empty or there is a malfunction in the BlueTec exhaust aftertreatment system the indicator lamp lights up A display message also appears In this...

Page 17: ...xhausted Segments All segments are off Display Standard onboard computer 0 l Plus onboard computer Refuel AdBlue Indicator lamp If the AdBlue supply is exhausted or there is a malfunction the engine p...

Page 18: ...in steering lock to drive position During the display check the warning buzzer sounds for about 1 second the segments of the status indicator light up yellow all the indicator lamps in the instrument...

Page 19: ...s indicator see page 27 System abbreviation or fault symbol When a display message is shown on the Standard onboard computer the display field shows the system abbreviation 5 of the affected control u...

Page 20: ...and cause an accident For this reason only operate the onboard computer when the vehicle is stationary with the parking brake applied Menu structure Description Default display If the control pad is...

Page 21: ...official purposes Condensation q Condensation reset Reset button Condensation ok The menu only appears in conjunction with a relevant display message see page 31 In some cases the condensation message...

Page 22: ...n During the display check the warning buzzer sounds for about 1 second the segments of the status indicator light up yellow all the indicator lamps in the instrument panel light up for about 2 second...

Page 23: ...age is shown on the Plus onboard computer due to a fault the display shows the system abbreviation of the affected control unit or a fault symbol e g if the coolant temperature is excessively high Sys...

Page 24: ...trol pad or repeatedly until the desired submenu is highlighted in the display Press control pad to open the highlighted submenu Another submenu list or the desired display e g Oil level O K appears E...

Page 25: ...o technical modifications i Home menu The home menu follows a circular pattern and contains the following displays depending on the vehicle equipment Default display with speed Date display Info displ...

Page 26: ...an be displayed The following main menus and submenus can be selected 1 Speed display 2 Time 3 Trip mileage Check Info AdBlue tank see page 25 Driver data Reservoir pressure see page 25 Oil level see...

Page 27: ...circuit 1 2 Reservoir pressure brake circuit 2 The reservoir pressures are displayed as bar graphs Oil level Oil level O K or Oil 2 5 l Check engine oil level with engine at operating temperature abo...

Page 28: ...by pressing the Reset button When reset the message O K appears in the display Diagnosis menu Call up home menu Diagnosis main menu and and submenu Description Control unit list BS FR INS and MB obje...

Page 29: ...es can be canceled and called up at a later time If an indicator lamp lights up with the display message it will not go out again even when the display message is confirmed In the case of significant...

Page 30: ...ghts up yellow in particular operating states e g when a power take off has been activated The status indicator lights up red for malfunctions of high priority e g when the alternator is defective Dis...

Page 31: ...situation Follow the instructions and observe the additional information in the display Have the affected system checked and repaired as quickly as possible at a qualified specialist workshop possessi...

Page 32: ...isit a workshop at the first opportunity Risk of accident G Malfunction in brake system of trailer semitrailer indicator lamp k lights up The handling and braking behavior may change i The display mes...

Page 33: ...parking brake before switching on the PTO Condensation in compressed air reservoir The condensation level in the compressed air reservoirs is too high Even at temperatures around freezing 0 C condens...

Page 34: ...on Power reduced The coolant temperature is too high The engine output is automatically reduced Reduce speed and shift to a lower gear if necessary Make sure that the air supply to the radiator is not...

Page 35: ...e vehicle as soon as possible taking into account the traffic situa tion apply the parking brake and switch off the engine Wait about 10 seconds and restart the engine If the engine is still running i...

Page 36: ...If the AdBlue supply is not topped up the message reappears the next time the engine is started Refuel diesel refueling AdBlue recommended The fuel supply is down to the reserve level Fill the fuel ta...

Page 37: ...ive After the instrument panel function check Fuse for brake lamps is defective i The display message consists of 2 parts Press button to see the 2nd part Check and replace the appropriate fuses Check...

Page 38: ...lfunction in brake system of trailer semitrailer indicator lamp k lights up The handling and braking behavior may change i The display message consists of 2 parts Press button to see the 2nd part Have...

Page 39: ...display message does not reappear the next time the engine is started The indicator lamp goes out The full engine power is available again Power reduced There may be fault The indicator lamp flashes T...

Page 40: ...ed before corners in particular Have the steering system checked at a qualified workshop Retarder shutoff not possible Service required Malfunction in the retarder control The retarder is not switched...

Page 41: ...situa tion Switch off engine and apply parking brake Check engine oil level via the Stan dard onboard computer see page 48 or the Plus onboard computer see page 48 and top up engine oil if necessary...

Page 42: ...ave the fault recti fied 1 2 Gear 3 4 Shift not possible The gearshift has shifting problems In extreme cases the vehicle is no longer drivable Stop the vehicle as soon as possible taking into account...

Page 43: ...tch off engine and apply parking brake Notify a qualified specialist work shop Brake reservoir pressure too low Risk of accident G The reservoir pressure in the spring loaded brake and or service brak...

Page 44: ...AGN Automatic transmission MR Telligent engine control BS Telligent brake system NR Telligent level control EAB Electronic trailer brake PSM Parameterizable special module FFB Radio remote control RS...

Page 45: ...ock see page 91 v Acceleration skid control ASR d Apply brake Brake pressure 1 Supplemental restraint system l Level control tractor vehicle and trailer o Excessive height tractor vehicle and trailer...

Page 46: ...he Instrument display check the indicator lamp lights up briefly and goes out again if there is no malfunction The indicator lamp flashes At the same time the display shows a display message with yell...

Page 47: ...l lights up If the indicator lamp 7 is constantly lit the transmission oil temperature in the automatic transmission is too high Switch off retarder Stop the vehicle as soon as possible taking into ac...

Page 48: ...the same time The operational safety of the vehicle is at risk Engine damage is possible Top up engine oil or Tow the vehicle away Malfunctions in certain electronic systems The operational safety of...

Page 49: ...Subject to technical modifications i Display failure Important operating information warnings or service indicators in the display can no longer be shown Tow the vehicle away With lights switched on...

Page 50: ...ngine oil level in the display Plus onboard computer To check the engine oil level the vehicle must be parked on level ground and the engine must be at operating temperature and must have been switche...

Page 51: ...shows N and the necessary top up quantity or O If a correct engine oil level reading is not possible the display shows P and a message Open maintenance flap Unscrew and remove cap 1 on oil filler neck...

Page 52: ...il level in the form of a code or a fault code Transmission oil level display If the indicator lamp 7 lights up or flashes while driving the temperature of the transmission oil or coolant is too high...

Page 53: ...ngine speed too low Make sure engine is at idle speed oL 59 Engine speed too high Make sure engine is at idle speed oL 65 Transmission is not in neutral N Shift transmission to neutral N oL 70 Transmi...

Page 54: ...transmission to N position and wait about 30 seconds Switch off engine Tilt cab forwards see page 91 Start engine with the cab tilted and run at idle speed see page 95 Remove oil dipstick 1 If the tr...

Page 55: ...kdown Services Subject to technical modifications i Fuel system overview example 1 AdBlue tank 5 Fuel filter 2 Fuel tank with fuel pump unit 6 High pressure pumps 3 Hand pump example Location of hand...

Page 56: ...k The main fuel tank is usually located on the right hand side of the vehicle frame The main fuel tank can be recognized by the fuel pump unit Additional fuel tank Additional fuel tanks may be mounted...

Page 57: ...Only use AdBlue that conforms with DIN 70 070 Special additives are not permissible If AdBlue comes into contact with painted or aluminum surfaces during refueling rinse off the affected areas immedia...

Page 58: ...pump location A hand pump is integrated into the top section of the fuel prefilter housing The fuel prefilter may be installed in various locations depending on the vehicle version 1 Hand pump 2 Shuto...

Page 59: ...off fuel supply only when the fuel prefilter is installed at the height of the tank To do this turn knurled screw 4 clockwise Operate hand pump 3 and collect the water fuel mixture Tighten drain screw...

Page 60: ...w 2 Slacken drain screw 2 Operate hand pump 3 and collect the water fuel mixture Tighten drain screw 2 Open knurled screw 4 on fuel prefilter Bleeding Remove cap from main fuel tank Slacken bleed scre...

Page 61: ...e assistance 59 Guidelines for Breakdown Services Subject to technical modifications i Overview of electrical system 1 EMERGENCY OFF switch on carrier frame see page 60 3 EMERGENCY OFF switch on dashb...

Page 62: ...er supply Turn the vehicle key in the steering lock all the way back Press cover down until it clicks into place Turn vehicle key in steering lock to drive position EMERGENCY OFF switch on battery car...

Page 63: ...batteries are visibly damaged are frozen or the fluid level has dropped below Min see Min Max mark on battery housing Replace the batteries Discharged batteries may freeze at temperatures of 10 C In...

Page 64: ...into your eyes If acid splashes in the eyes flush it out immediately with clean water and seek medical attention without delay C Keep children away Children are incapable of appreciating the dangers...

Page 65: ...ollowing work Set clock Deactivate anti theft system on audio device radio see manufacturer s operating instructions Risk of injury G There is a risk of short circuit if the positive terminal of the c...

Page 66: ...latches 1 Remove the bottom cover 3 first and then the top cover 2 Risk of fire G Do not use fuses with a higher amperage than that specified This could result in damage to the electrical system and...

Page 67: ...dio 24 V frequent stop brake terminal 30 10 A F17 Blower air conditioning 20 A F5 Work lamp heavy vehicle fee system terminal 30 10 A F18 Radio telephone auxiliary heater fax Instrument terminal 15R 1...

Page 68: ...Engine control terminal 15 hazardous goods EMERGENCY OFF 10 A F38 Tachograph Instrument airbag terminal 15 10 A F31 Outside mirror adjustment SCR frame module terminal 15 10 A F39 Horn air horn Toll C...

Page 69: ...4 Comfort locking system 10 A F11 SCR frame module terminal 30 15 A F5 Electropneumatic brake hand lamp socket terminal 15 10 A F12 Cargo liftgate 10 A F6 12 V sockets 15 A F13 Transmission control 10...

Page 70: ...Subject to technical modifications i Transmission Overview of transmissions The Atego is available with three different versions of transmission shift Manual gearshift system see page 69 Automatic tr...

Page 71: ...stem checked and repaired as quickly as possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary safety relevant work Mercedes Benz rec...

Page 72: ...k between 3rd and 4th gear or between 5th and 6th gear Shift range change If it is not possible to change gear while driving the journey can be continued in the engaged gear as long as circumstances a...

Page 73: ...k of accident G Do not shift down to braking on slippery roads The drive wheels could lose grip and the vehicle could start to skid If the indicator lamp 7 lights up while driving the temperature of t...

Page 74: ...not depress the accelerator pedal Press button D 6 or R 8 Vehicles with backup warning system The backup warning system sounds in reverse gear Only release the brakes when ready to move off otherwise...

Page 75: ...s possible at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work Mercedes Benz recommends a Mercedes Benz service center for this work I...

Page 76: ...Telligent automatic gearshift system shifts to 1st gear start off gear automatically The selected gear flashes briefly on the right hand side of the gear indicator and then changes to the left hand po...

Page 77: ...ent message is shown in the display Turn the vehicle key in the steering lock all the way back and wait at least 5 seconds The displays in the gear indicator disappear Repeat teach in process Minor te...

Page 78: ...sition Start the engine within 10 seconds when the transmission neutral position N flashes in the display Release neutral button and function button The teach in process is complete i If fault code a...

Page 79: ...g Apply parking brake GS 20 The display shows U Charge or replace the battery GS 21 The clutch pedal was released too early or too late during the teach in process Depress the clutch pedal at the righ...

Page 80: ...sage is shown in the display If the electronic system fails the brake system is controlled pneumatically in two circuits Braking behavior is significantly different from that of the intact system The...

Page 81: ...p brake is active and is ready to operate again when the vehicle moves off Releasing the frequent stop brake Depress accelerator pedal As soon as the vehicle moves off the frequent stop brake is relea...

Page 82: ...oes out Deactivating the hill holder Press bottom of hill holder switch The indicator lamp k in the instrument panel goes out Risk of accident G Do not activate the hill holder in wintry road conditio...

Page 83: ...compressed air system requires a minimum pressure of about 10 5 bar Separate filling of the air suspension system see page 90 Tire inflation connection The four circuit protection valve and the compre...

Page 84: ...eumatically If it is not possible to fill the system via the tire inflation connection or the coupling head see page 81 circuit 3 see page 78 can be filled via the filling valve On vehicles manufactur...

Page 85: ...se position 2 Restoring spring loaded parking brake to operational state Fill brake system up to cutoff pressure Secure vehicle using wheel chocks to prevent it from rolling Move lever of parking brak...

Page 86: ...t 4 is firmly seated at the spring stop Screw nut 2 with washer 6 onto release bolt 4 Release spring in spring loaded cylinder mechanically by tightening nut 2 in clockwise direction Swing lever of pa...

Page 87: ...ll brake system up to cutoff pressure Move lever of parking brake valve to release position Unscrew nut 2 with washer 6 from release bolt 4 Unscrewing the nut 2 retightens the spring in the spring loa...

Page 88: ...control operating unit beside driver seat 4 Air spring bellows with test valve 2 bellows system 2 Compressed air reservoir 5 Valve block for front or rear axle 3 Air spring bellows 4 bellows system 6...

Page 89: ...it i Vehicles with air sprung rear axle The chassis frame can only be raised or lowered at the rear axle Vehicles with full air suspension The chassis frame can be raised or lowered at the front and r...

Page 90: ...Raise 8 or Lower 9 button to set the desired height of the chassis frame Start engine and run until the pressure regulator cuts out Press and hold down the STOP button a Turn the vehicle key in the s...

Page 91: ...The chassis frame rises or drops to the stored height automatically When the normal level driving position is reached the display A or B in the display and the status indicator go out Vehicles with P...

Page 92: ...connection for the air suspension is located on the left hand side of the vehicle below the implement carrier Test connections If the air suspension control system fails the test connections 3 4 and 6...

Page 93: ...gearshift lever and in front of the cab clear for safety reasons Close all doors and stowage compartments in the cab Close all outside flaps Additionally secure the vehicle using wheel chocks to preve...

Page 94: ...2 Tilting back to driving position Unlock safety catch at right hand step using op erating lever Tilt cab back to driving position until it engages audibly in the cab lock If necessary push the cab i...

Page 95: ...work and all work on safety relevant systems is performed by a qualified specialist workshop Tilting the cab forward The tilt pump is located behind the cab on the right hand side Move valve lever on...

Page 96: ...ise there is a danger that the cab lock could open by itself while driving and the cab could tip forward if the vehicle brakes hard When the cab is tilted back to the driving position the tilt pump mu...

Page 97: ...n the start pushbutton 2 until the desired engine speed is reached When the start pushbutton 2 is released the engine continues to run at the set speed Switching off the engine With the engine running...

Page 98: ...f a gear is engaged the start stop pushbutton 1 is inoperative Starting the engine and increasing the engine rpm Press and hold down the start stop pushbutton 1 The engine starts and the rpm increase...

Page 99: ...l If possible fill the compressed air system from an external source before tow starting see page 81 If the engine is not running only tow start the vehicle on a straight stretch of road no power stee...

Page 100: ...oupling pin 1 in the catch with an audi ble click Tow starting vehicles with manual transmission Fully depress clutch pedal On 6 speed transmissions Shift to 4th or 5th gear On 9 speed transmissions S...

Page 101: ...be shown in the display Tow start vehicle At about 20 km h slowly depress accelerator pedal The electronic system engages the clutch automatically Immediately after the engine starts Shift transmissi...

Page 102: ...s on stopped engine transmission and or axle damage Stopped engine Page 107 Transmission transfer case damage Page 107 Front axle damage Page 107 Rear axle damage Page 107 Drive shafts Ascertaining th...

Page 103: ...t your driving style to suit the more difficult conditions Risk of accident G When you start to move a vehicle with the front axle raised and the acceleration skid control ASR switched on the ASR may...

Page 104: ...either side of the vehicle Pay attention to the height of the vehicle when driving through tunnels and bridges Ensure that the vehicle to be towed has an adequate power supply Ensure that the vehicle...

Page 105: ...fer case may only be shifted when the vehicle is stationary The neutral position of the transfer case is only necessary when changing from the road position to the off road position Vehicles with Tell...

Page 106: ...constant reservoir pressure in the compressed air system Maintenance flap cover Removing the cover Open and secure maintenance flap Unscrew mounting bolts 1 and remove cover Risk of injury G When the...

Page 107: ...front for towing Un screw connection 21 1 on service brake valve On vehicles raised at the rear for towing Un screw connection 22 2 on service brake valve Identical adapters are required for both bra...

Page 108: ...equired If the spring loaded parking brake cannot be reliably released pneumatically release it mechanically see page 83 When filling directly at four circuit protection valve Test connection 22 for r...

Page 109: ...ith the operating unit see page 86 Damage to the rear axle differential On vehicles with more than one driven axle or insufficient air pressure in the compressed air system Engage differential lock wi...

Page 110: ...p in the instrument panel must not light up Disengage the clutch select a gear and gradually release the clutch pedal Transmission damage 1 The engine stalls without propeller shaft 2 moving Transfer...

Page 111: ...cable connector 1 from shift cylinder housing 2 Unscrew switch using socket wrench size 24 mm Carefully screw bolt 3 all the way into shift cyl inder housing 2 Bolt M 18 x 1 5 x 60 mm Special tools s...

Page 112: ...rn the vehicle key in the steering lock all the way back or remove Engage differential lock interwheel differential lock with bolt Unscrew bolts 1 on wheel hubs Place oil pan under wheel hub Collect e...

Page 113: ...ways use a tow bar for towing If possible tow the vehicle empty unload the vehicle if necessary in order to avoid consequential damage Load the coupling jaw with no more than half the permissible gros...

Page 114: ...hen towing entire combinations route an ABS cable from the towing vehicle to the trailer or semitrailer 5 pin Overview of towing options Risk of accident G Trailer semitrailer with ABS EAB When towing...

Page 115: ...of inflatable jacks if necessary Pay attention to tie rods soundproofing panels and the level control system on vehicles with full air suspension Move the lift fork 2 under the vehicle and set to the...

Page 116: ...using a chain or strap 1 Lateral forces arising when a laden vehicle is raised can lead to distortion at the cargo area Set rear axle to driving level see page 88 Secure the vehicle to the lifting dev...

Page 117: ...in the support fixture or lifting device and secure Fasten lifting device with spring support 1 to leaf spring and secure Secure the vehicle with a chain hoist 2 to pre vent it from slipping In certa...

Page 118: ...poiler Detach wind guides Raising by the rear wheels Push the lift fork under the vehicle Set the lift fork to the track width and tire size Raise the vehicle and secure at the wheels with straps and...

Page 119: ...the rear crossmember semitrailer tractors only If necessary detach the trailer hitch or towing coupling Unfasten the wiring harness in the crossmember and the compressed air reservoir if necessary and...

Page 120: ...ys 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 possible to unload the ve...

Page 121: ...s Recovering by the axle sunken vehicles Attach towing straps to axle housing Fit the straps 1 so that detachable parts stabi lizer bars hoses and cables are not damaged Recovery at the front coupling...

Page 122: ...sion and brakes kingpins steering knuckles Rear axle s Rear axle housing and attaching parts for suspension and brakes Axle joints Springs spring shackles spring bracket Air spring bellows detachable...

Page 123: ...ecial tools and bolts are not included in the vehicle tool kit Bolt M 18 x 1 5 x 60 mm for locking the rear axle differentials see page 109 Adapter for compressed air connection 1 M 18 x 1 5 part no A...

Page 124: ...Guidelines for Breakdown Services Subject to technical modifications i Special tools Compressed air hose Lifting fork 3 4 5 2 2 Connection 3 Hose 4 Adapter 5 Coupling head 6 7 6 Front axle lifting fo...

Page 125: ...8 mm 3 Hole diameter 17 mm Item Designation Dimension 1 Diameter 194 mm 2 Hole circle radius outside 82 mm 3 Hole circle radius inside 78 mm 4 Angle outside inside radius 22 5 5 Hole diameter 15 mm 6...

Page 126: ...Guidelines for Breakdown Services Subject to technical modifications i Special tools The following special tools aids are recommended by Mercedes Benz Inflatable jack Lift height up to 200 mm lift fo...

Page 127: ...ing jaw 111 119 Cover removing 104 Crossmember 117 D Detachable frame parts 118 Diesel fuel filler neck 55 Differential lock 109 Display 24 Display messages 27 Display messages with red status indicat...

Page 128: ...reservoirs 81 Electrical system 59 Instrument panel 11 P Parking brake 82 Permissible pulling forces 119 Plus onboard computer 20 Positive terminal 63 Preparations for tow starting 97 Pressure booster...

Page 129: ...m 98 Telligent automatic gearshift system 99 Transfer case switching 103 Transmission 68 Automatic transmission 71 Manual gearshift system 69 Overview 68 Telligent automatic gearshift system 73 Transm...

Page 130: ......

Page 131: ...Towing Recovery Atego Daimler AG GSP OI HPC R 822 D 70546 Stuttgart Technical status 10 2008 Towing Recovery...

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