Tour of the vehicle 2

Mercedes-Benz Truck product overview 2.1

2 Tour of the vehicle

2.1 Mercedes-Benz Truck product overview

Product overview
The Mercedes-Benz Truck division has changed continually over the years. Not just in terms of
the appearance of the vehicles or the engines used, but also in terms of their electrical compo-
nents and networking. The following is an overview of current Mercedes-Benz Truck products.

Actros 5 (model series 963)

Atego Euro VI (model series 967) Truck_000170
TT_00.00-028656-FA

Arocs (model series 964)

TT_00.00-028654-FA

The Antos model series is discontinued following the launch of the Actros 5. The Actros 5
adopts its previous vehicle and cab variants.

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2 Tour of the vehicle
2.2 Division into groups for tour of the vehicle

Structure of chassis identification number (VIN)

The vehicle identification number of model series 963, 964 and 967 is made up as follows (here
based on the example of an Actros):
WDB 963 003 1 L 000001
Manufacturer Model designa- Type/ Steering Plant code Chassis end
code tion number wheel configu- number
ration
WDB = Wörth 963 = On-road Left (1) (000000 to
model series, vehicle Right (2) 999999)
WDF = Aksaray 964 = Off-road
model series, vehicle
W1T = Wörth and 967 = Atego
Aksaray Euro VI
model series)

The wheelbase is not coded in the chassis number.

2.2 Division into groups for tour of the vehicle

To get an impression of the Actros 5, the practical exercise starts with a tour of the vehicle.
Please always conduct this tour by focusing on the electrical changes in particular.

Truck_001568

Please complete the following sections in two groups.

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 Tour of the vehicle 2
Tour of the vehicle - vehicle exterior 2.3

2.3 Tour of the vehicle - vehicle exterior

Exercise 1 Look at the vehicle and note down any distinguishing exterior features, focusing on electrical
components in particular.

2.4 Tour of the vehicle - cab interior

Exercise 2 What changes/new features do you notice compared with the previous Actros 4 model, focus-
ing on electrical components in particular?

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3 On-board electrical system
3.1 Battery

3 On-board electrical system

3.1 Battery
Atego (model series 967)
Code Capacity Weight (2 ea.)
E1A 115 Ah 77 kg Low-maintenance
E1E 100 Ah 52 kg Low-maintenance
E1G 135 Ah 115 kg Low-maintenance
E1H 165 Ah 162 kg Low-maintenance

Actros (model series 963), Arocs (model series 964)

Code Capacity Weight (2 ea.)
E1B 170 Ah 94 kg Low-maintenance
E1C 220 Ah 120 kg Low-maintenance

The 220 Ah battery is mainly installed in the long-haul Actros truck (model series 963). Drivers
"live" in these vehicles, which means that the batteries are subjected to the greatest stresses
and are often heavily discharged.
The lead battery does not make use of pure lead but an alloy (PbSb) consisting of lead (Pb) with
some antimony (Sb). This makes the material harder. However, the disadvantage of antimony is
that these batteries consume a certain amount of water and self-discharge to some extent.
These two characteristics mean that these batteries cannot be designated "maintenance-free".
However, there are also batteries which use a lead-calcium alloy (PbCa). The water consump-
tion and self-discharge tendencies of these batteries are much lower. This means that they are
suitable as maintenance-free batteries. The disadvantage, however, is that they are seriously
damaged after deep discharging and then often have to be replaced.

The current truck model series have hybrid batteries (wet batteries) installed as standard.
In this case, the negative plate's alloy contains calcium while the positive plate is alloyed
with antimony. These batteries are designated "maintenance-free".

Testing and charging a wet battery

The battery is tested using the Midtronics tester. Work instructions AR54.10-N-1129-01A
provide information on the procedure.
Please also note Service Information SI54.10-N-0003A

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 On-board electrical system 3
Battery 3.1

AGM battery, special equipment code E1Z

Absorbent Glass Mat (AGM) battery technology enables these fully maintenance-free batteries
to deliver up to 25% more power while also having a much longer service life than conventional
wet batteries.
Their key advantages include better cycle strength as well as a short charging time and higher
current capacity. In addition to this, their greater vibration resistance helps to ensure a longer
service life.
With comparable max. capacity, the AGM batteries have up to 25% more usable capacity than
conventional wet batteries, since the threshold for damaging deep discharge is lower and the
battery reaches its full capacity again more quickly while driving after discharging.
The AGM batteries are about 16 kg heavier than the wet batteries in total, with 2 x 12 V/
220 Ah, maintenance-free (E1C). They weigh 2 x approx. 68 kg = approx. 136 kg.

Special equipment "E1Z - AGM batteries" 2 x 12 V/220 Ah, maintenance-free

Truck_001569

Testing and charging an AGM battery

The AGM batteries cannot be tested with the Midtronics battery tester as previously. Due to
the battery's very low internal resistance, the tester either cannot perform the test or deliv-
ers an incorrect test result. The test and warranty process has therefore changed for the
AGM battery. Warranty claims must now be accompanied by a report via smartphone app.

The "AGM Truck Test" app is available for this purpose. A detailed user guide and instruc-
tions can be found in XENTRY TIPS under GI54.10-N-069274

Additional information about possible retrofitting of the AGM battery can be found under
SI54.10-W-0066A

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3 On-board electrical system
3.1 Battery

Arrangement of batteries and B-junction box in Actros (model series 963) and Arocs
(model series 964)
Integral rear area - code C7T Batteries adjacent to one another - Batteries stacked above one an-
code C7J other - code C7K

Battery arrangement Battery arrangement Battery arrangement

TT_54.00-016361-FA TT_54.00-016362-FA TT_54.00-016363-FA

Arrangement of B-junction box on left

of frame Arrangement of B-junction box on the
TT_54.10-021857-FA
second battery
TT_54.10-021858-FA

Arrangement of B-junction box be-

tween the batteries
TT_54.10-021859-FA

B-junction box

B-junction box 8 mm stud

TT_54.10-021860-FA TT_54.10-022370-FA

The B-junction box contains the battery sensor connection The terminal 31 current tap for retrofitted equipment with
to the negative line (charger connection). high power requirements is carried out via the 8 mm stud
in the B-junction box

The only battery installation location on the Atego (model series 967) is on the left side. There
is no battery sensor and thus also no B-junction box.

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 On-board electrical system 3
Intelligent Battery Sensor (IBS) 3.2

3.2 Intelligent Battery Sensor (IBS)

Battery sensor, shown on vehicle with code C7T (integral rear area)
Truck_001570

G1 Battery

G1a Intelligent Battery Sensor (IBS)

Purpose of the battery sensor

The battery sensor determines the charge level and the starting capability of the batteries. It
sends this information on request via ASAM-LIN2 (LIN 16) to the Advanced Sensor and Actua-
tor Module (ASAM) control unit (A7).

Design
The battery sensor contains an electronic control unit for measured data acquisition and pro-
cessing (microcontroller), and a precision resistor.

Function
The battery sensor calculates the batteries' charge state and starting capability by measuring
the battery voltage at the battery terminals, the battery temperature at the battery ground ter-
minals, and the current via the voltage drop at the precision resistor.
The battery sensor sends the result of the calculation on request via ASAM-LIN 2) to the Advanced
Sensor and Actuator Module (ASAM) control unit (A7).

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3 On-board electrical system
3.2 Intelligent Battery Sensor (IBS)

Component description

HELLA battery sensor

TT_54.10-034127-SW

Nut M6
1 Terminal 7
Tightening torque 7 +/- 1 Nm
2 Housing 8 Terminal screw M6

3 Shunt precision resistor 68 µΩ 9 Bolting plate

Hexagon head bolt M10
4 Electrical connection (3-pin) 10
Tightening torque max. 17 Nm
Hexagon head bolt M8
5 Fastener 11
Tightening torque max. 14 Nm
6 Washer

The intelligent battery sensor is attached to the negative terminal of the lower starter battery
and consists of mechanical components, an electronic unit, and the corresponding software.
The mechanical components consist of the battery terminal connection with the ground cable
on the battery. This is done using the terminal screw (8) and the accompanying nut (7).

The electronic unit comprises a printed circuit board with the electronic analysis system and a
microprocessor. There is also a shunt precision resistor and an NTC temperature sensor. The
electrical connection has three pins.

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 On-board electrical system 3
Intelligent Battery Sensor (IBS) 3.2

The pin assignment is as follows:

Pin 1 = 12 V
Pin 2 = LIN bus connection

Pin 3 = 24 V

Function
The intelligent battery sensor (IBS) records:
 The battery temperature
 The battery terminal voltage
 The battery current, charging current and discharge current.
The 68 µΩ shunt precision resistor causes a voltage drop, which allows calculation of the start-
er battery's current and voltage. Pin 3 (24 V) supplies the sensor with voltage. The temperature
is recorded at the terminal clamp by an NTC resistor and analyzed by the electronic unit. The
battery sensor transmits the collected data to the ASAM control unit via pin 2 (LIN bus). The
ASAM control unit evaluates this data and automatically initiates the extended consumer
shutoff function if the battery status is low. The ICUC (Classic Cockpit) or ICS (Multimedia
Cockpit) instrument cluster informs the driver that the consumer shutoff function is active and
prompts the driver to start the engine.

Retrofitting
The M8 hexagon head bolt (11) should be tightened to max. 14 Nm and is intended for retrofits
by body manufacturers ('bodybuilders').

The body/equipment mounting directives must be consulted and observed for every retrofit!
You will find this information in Book II, Chapter 7, Electrical system.
It is available on the following website:
https://bb-portal.mercedes-benz.com

Battery replacement
If the battery type, ASAM or battery sensor are changed, the corresponding battery parameters
must be adapted. Go to ASAM and ADAPTATIONS to call up the corresponding menu item and
perform parameterization. The battery sensor can be found under INITIAL STARTUP, while the
battery, battery disconnect switch and consumer shutoff are under PARAMETERIZATION.
As soon as a battery is replaced and the same battery type is reinstalled, the battery sensor
must be notified of this by means of a reset command. The data compiled about the removed
battery are then erased.
When screwing the vehicle ground line to the outer M10 battery pin (10), the connection should
be tightened to the appropriate torque of max. 17 Nm. Otherwise torque may be applied to the
shunt/pin plate solder connection (5).

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3 On-board electrical system
3.3 Alternator management

3.3 Alternator management

When the vehicle is started, the starter requires a high starter current. It obtains this from the
battery. During normal driving, consumers - e.g. diesel injection system, control units, lighting etc.
- also require power. The vehicle needs a three-phase alternator to provide this power and be able
to recharge the battery.

The alternator is mounted on the side of the engine and is powered by a belt drive. The alterna-
tor is designed to induce a voltage when the engine is running, which supplies both the on-
board electrical system and the batteries. As the engine rpm increases, the induced voltage al-
so increases, and vice versa.

Example of alternator installation position

TT_01.00-028707-FA

1 Alternator

The alternators are designed as compact alternators with different output ratings. The following
alternators are used in the Actros (model series 963) and Arocs (model series 964).
 E1N - 28 V/100 A alternator with 2800 W
 E1M - 28 V/150 A alternator with 4200 W
 E1T - 24 – 30 V/100 A LIN alternator with 2800 W
 E1U - 24 – 30 V/150 A LIN alternator with 4200 W

Only the following alternator is installed in the Atego (model series 967):
 E1N - 28 V/100 A alternator with 2800 W

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 On-board electrical system 3
Power Distribution Module (PDM) 3.4

The compact alternators are characterized by:

 High thermal operational reliability
 Automatic adaptation of the alternator voltage by multifunction regulator
 Overvoltage protection

The (LIN = Local Interconnect Network) alternator has intelligent control, which recuperates
current and relays it to the truck's electrical system (battery/on-board electrical system).
The intelligent control enables the alternator to charge the battery with maximum power
(U > 28.3 V) during engine braking. When the engine braking torque decreases
(U < 28.3 V), the recuperated energy is relayed to the on-board electrical system. It is
therefore also called a "regulated alternator".

3.4 Power Distribution Module (PDM)

Versions
The consumers installed in the Actros 5 are protected by two power distributors (PDM).

PDM arrangement
W54.10-A003-79-color

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3 On-board electrical system
3.4 Power Distribution Module (PDM)

Chassis PDM (A152)

Chassis PDM (A152) X15.8 connector Pin assignment
 Pin 1 = F2 (EAPU)
 Pin 2 = F1 (EPAC)
 Pin 3 = F8 (EPAC)
 Pin 4 = F3 (EPAC)
 Pin 5 = F4 (CLCS)
 Pin 6 = F5 (ASA)
 Pin 7 = F6 (Trailer)
 Pin 8 = F7 (Trailer)

Truck_000083

Truck_000084

The Chassis PDM supplies consumers outside the cab with protected battery voltage. There are
changes to the component compared with the Actros 4 power distributor. The CLCS, EAPU,
ASA, and components of the EPAC are supplied with protected battery voltage via the addition-
al connector (X15.8). These consumers are protected by means of ATO plug-in fuses (F1/A152
to F8/A152).
Consumers with higher power consumption are plugged into connections X2 - X13. They are pro-
tected by safety fuses held in place by screws. Power is supplied from the battery to the PDM via
the connections X1 or X14, depending on the vehicle variant.

Cab PDM (A8)

The Cab PDM (A8) is the central distributor point for the voltage supply around the cab. It per-
forms the same classic protection and voltage distribution tasks as the SSAM in the Actros 4. The
consumers connected there are supplied with voltage and protected by means of relays and fus-
es. Its sole purpose is power distribution. It has no diagnostics capability. The Cab PDM is located
in the electronics compartment at the rear.

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 On-board electrical system 3
Power Distribution Module (PDM) 3.4

Cab PDM (A8) design

Front view of Cab PDM

ATO fuses and mini fuses for protecting consumers are located on the front side of the Cab
PDM. The Cab PDM manages eight relays and various connectors for signal reception to enable
relay actuation and supply of power to the consumers in the vehicle interior.

Cab PDM (A8)

Truck_000012

Rear side of Cab PDM

The Cab PDM (A8) is supplied with voltage from the Chassis PDM (A152) via two supply lines.
The connections are located on the rear side of the Cab PDM.
The protected feed line to the Cab PDM coming from the Chassis PDM is connected at the
screw connection. It has a cross-section of 35 mm2.
The connector at input X11 is the second supply line with a cross-section of 10 mm2.
The rear of the PDM is accessed from the outside through the front-end flap.
A threaded connection on the left side or right side of the engine, depending on the vehicle var-
iant coding, is used to provide the ground connection.

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3 On-board electrical system
3.4 Power Distribution Module (PDM)

Rear view of Cab PDM

Truck_000085

Function
The relays arranged on the Cab PDM are activated by the ASAM (A8). The voltage supply to the
relay input is internally connected. The consumers supplied by the relay are protected after the
particular relay output. A relay output supplies the connected consumers with protected volt-
age via several safety fuses.

Relay arrangement K1 - K8
K1 Control terminal 15/1
K2 Supply D+ consumer
K3 Trailer brake lamp
K4 Bistable relay second stage consumer shutoff
K5 Air conditioning supply, door modules and radio

K6 Air conditioning blower motor, seat heating, cigarette lighter

K7 Control terminal 15/2
K8 Bistable relay first stage consumer shutoff

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 On-board electrical system 3
Power Distribution Module (PDM) 3.4

Cab PDM – Internal circuit diagram, relay K1 - K8 activation

Terminal 15/1

Terminal 15 A8 - K1 1/2
Truck_001571

Terminal 15 A8 - K1 2/2
Truck_001572

Terminal D+

Terminal D+ A8 - K2
Truck_001573

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3 On-board electrical system
3.4 Power Distribution Module (PDM)

Terminal 54

Terminal 54 A8 - K3 "Trailer brake lamp"

Truck_001574

Consumer shutoff

Consumer shutoff A8 - K4
Truck_001575

Terminal 15 - ACC

Terminal 15 A8 - K5 "ACC"
Truck_001576

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 On-board electrical system 3
Power Distribution Module (PDM) 3.4

Terminal 15 - IGN. ACC

Terminal 15 A8 - K6 "IGN. ACC"

Truck_001577

Terminal 15/2

Terminal 15 A8 - K7
Truck_001578

Consumer shutoff

Consumer shutoff A8 - K8
Truck_001579

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3 On-board electrical system
3.4 Power Distribution Module (PDM)

Retrofitting electrical consumers

Retrofitting on Chassis PDM

For protected voltage supply of a retrofitted electrical consumer, it is possible to connect the
consumer to connection X12 at A152. Currents up to 200 A can be supplied at this connection
for retrofits. Only fuse links of type SF51 as per MBN 8820-5 may be used for protection.

Arrangement on Chassis PDM

Truck_000086

Retrofitting for additional consumers

Connection X11 on the Chassis PDM is used to supply voltage to retrofittable additional 24 V
devices in the cab (special equipment code E9G).
The feed line runs from the Chassis PDM to the additional current stems for the adaptation in the
cab (FF connector). This safeguards the retrofit for currents over 10 - 80 A. It is therefore possible
to install additional electrical devices (e.g. microwave).
The feed line is protected with an 80 A fuse in the Chassis PDM. The wire cross-section is
16 mm2. The maximum permissible current draw is 80 A.
If connection X11 is unused, it is possible to subsequently route an additional voltage supply to
the Cab PDM from there. This enables the retrofitting of additional consumers up to max. 80 A.
Only fuse links of type SF30 MBN 8820 may be used to protect the consumers.

If there are retrofits on the power distributor or on the vehicle, the appropriate wire cross-
sections, seals and fuses must be used. The wires must be routed safely. They are not
allowed to chafe and must be securely fastened.

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 On-board electrical system 3
Power Distribution Module (PDM) 3.4

CAUTION

Due to the ground return, all of the connections described before can take a total of maximum
200 A long-term (maximum 250 A if limited to 60 s). The relevant provisions in the
Body/Equipment Mounting Directives must be observed.

Retrofit options for additional consumers on Cab PDM (A8)

The functions of connector X7 on the SSAM in the Actros 4 have been split in vehicle generation 5.
Voltage taps for terminals 15, 30, 31 and D+ can be at the Cab PDM plug-in connector (A8) at
connector X15.6 in vehicle generation 5.

Cab PDM
W54.10-A005-78-color

1 Connector A8. X15

A8 Cab PDM

Connector X15 pin assignment

Pin Terminal designation Max. current
X15.6/1 Terminal 31 10 A
X15.6/2 Terminal 15 5A
X15.6/3 D+ 5A
X15.6/4 Terminal 31 10 A
X15.6/5 Not assigned
X15.6/6 Terminal 30 10 A

The current consumption of all consumers subsequently connected at connector X15 may
not exceed 10 A.

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