Trucks - Maintenance Technician (MT) Mercedes-Benz Product Technology Maintenance and Service Basic Training Information & Hand-Out

Trucks • Overall Vehicle STAR
DIAGNOSIS Basic Training
Trucks • Maintenance
Technician (MT)
Mercedes-Benz Product
Technology
Maintenance and Service
Basic Training
Information & Hand-out
t Issue date 01/08

71_01 20.11.98 I_D71_01
This document is for training purposes only and is not subject to ongoing revision.
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1511 6146 02 - 2nd edition 01/08 144

Contents
Page Title Page Title

1 Preface 78 Front Axles
2 Daimler AG 81 Rear Axles
11 The Technical Milestones 85 HL6 axle concept and super-wide tires
16 Overview of Light Vans 86 Brakes
18 Overview of commercial vehicles (excerpt) 90 Permanent brakes
22 Vehicle versions and designations 93 Steering
25 Cab 94 Integral rear end
31 Overview of gasoline engines 95 "KontAct" electronics concept
35 Overview of Diesel Engines 96 Telligent® systems
43 BlueTec diesel technology 100 Telligent engine system
46 Range-change transmission 101 Telligent® brake system
52 Transmission shift 102 Digital Monitoring Unit
62 6-gear synchromesh transmission 104 Maneuvering, tow-starting and towing
65 9-gear synchromesh transmission 106 Vehicle data card
68 16-gear synchromesh transmission 108 Overview of Design Groups
70 Mercedes PowerShift transmission - 16-speed 110 Workshop Information System WIS net
71 Mercedes PowerShift transmission - 12-speed 112 Meaning of Symbols in the Workshop Literature
72 Power take-offs 114 Xentry TIPS
76 Transfer case 116 Electronic Parts Catalog
01/08 Contents I
Commercial Vehicles Maintenance Technician Mercedes-Benz Product Technology Maintenance and Service Basic Training Information & Hand-out
Page Title Page Title
118 Damage Code 131 Maintenance
119 Online Vehicle Documentation System FDOK 135 ASSYST
123 Specifications for Operating Fluids 137 Telligent® maintenance system WS
125 Work Units 139 Special service procedures
01/08 Contents II
Preface
Welcome to the basic training course entitled

"Mercedes-Benz Product Technology - Maintenance and Service of
Commercial Vehicles" The qualification for the workshop specialist and workshop foreperson
This training course provides the information needed to carry out mainte- target group was specified in greater detail at Mercedes-Benz and struc-
nance and repair work on Mercedes-Benz passenger cars. The knowledge tured based on the specific requirements with regard to competence and
of the structure and the operation/function of the individual maintenance knowledge.
systems and items is consolidated during practical work. In order to make orientation easier for managerial staff and employees, a
The contents of this training course are a prerequisite for maintenance new model for the advancement of knowledge and competence was made
technicians to be able to reliably and effectively carry out the maintenance available.
operations on Mercedes-Benz commercial vehicles using the valid service
information.
Categorization of the job profiles and opportunities for further training
Customer contact Parts process
Workshop specialists (including forepersons)
specialists specialists
Diagnostic experts
Certified diagnostic technician

Certified Service Advisor Parts Process Specialist
(CSA) (PPS)
Repair technician (RT)
Tele- Comfort
Chassis Drivetrain
communication systems
Maintenance technician (WT)

Commercial or technical vocational training
(corresponds to a technical vocational training e.g.
(e.g. automotive administration assistant)
automotive mechatronics technician)
01/08 Preface 1
Daimler AG
Having a manufacturing tradition that not only reaches back 120 years, but Daimler AG is one of the world's leading automotive companies.
also includes the first car ever built and has a common history of more than Their passenger car brands include Maybach and Mercedes-Benz smart.
200 years, Daimler AG has been the world's leading automotive, transport
and service company right from the start. Their commercial vehicle brands include Mercedes-Benz, Freightliner,
Sterling, Western Star, Setra and Fuso.
All of the company branches dealing with the production of vehicles,
trucks, railroad engineering and aerospace engineering as well as financial Daimler AG Services provides financial and vehicle-related services.
services, have established themselves in the top positions of the particular
industrial sector.
Gottlieb Daimler and Karl Benz would have never been able to imagine the
scale their visions would have later on. Today, Daimler AG has the most Mercedes Car Group
extensive product portfolio and the most valuable brands in the automotive
industry.
Thanks to the excellent research and development achievements, these
brands always use the latest technologies in the particular segment and
offer the very best when it comes to innovation, design, safety, quality and
service.
01/08 Daimler AG 2
Commercial vehicles Buses
Strategic partners
Services Other activities

• EADS (European Aeronautic Defense and Space Company).
01/08 Daimler AG 3
History
On June 28, 1926, the "Daimler Benz AG" was formed from the "Daimler- The end of the war for the Sindelfingen plant came as early as in 1944.
Motoren-Gesellschaft" and the "Benz & Cie. Rheinische Gasmotorenfabrik" After repeated bombing raids, the plant was razed to the ground.
with the headquarters in Berlin and the administration in Untertürkheim.
Over the course of the following years, Daimler Benz vehicles continued to
make history. Successes in motor sports and rising sales figures as the
result of the development of innovative technologies made this possible
(refer to "Technical milestones").
• 1932: Check information on Vito V-Class. In a race on the AVUS in
Berlin, the 200 km/h record was broken. On May 20, 1945, work resumed in Sindelfingen with 120 employees. The
• 1934: The "Silver arrow" era began. first commercial vehicles, the 170V models, rolled out of the production
shops as early as in 1946.
Just before the war, the preproduction model of the KdF car was developed
in cooperation with Ferdinand Porsche.
The Germans did not drive with this vehicle until much later. Years of war
production followed. In 1943, vehicle manufacturing was abandoned and After years of planning, the first universally applicable motorized imple-
only wood carburetor motors were produced. ments were created in 1948, which are known today as Unimog.
01/08 Daimler AG 4
The years to follow were marked by economic boom, social development In the years to follow, Daimler Benz AG became a global corporation under
and increasing prosperity. The needs had changed and the market became then Chairperson and Chief Executive Edzard Reuter. A holding was formed
bigger. at the end of the 1980's following the merger and takeover of other com-
panies.
• 1952: Start of vehicle sales in the USA
• 1954: Reentry into motor sports • 1981: Takeover of "Freightliner"
• In 1957, as many as 50,000 people are working again for the company. • 1989: "DASA" (Deutsche Aerospace) was founded from the
companies Dornier, MTU, MBB and parts of AEG
• 1959: First crash tests on model 220
• 1989: The "Mercedes-Benz AG" was founded
• 1962: Construction of the commercial vehicle plant in Wörth
• 1989: Spin-off of the corporate unit "AEG-AG"
• 1990: "Debis" (Daimler Benz Inter Service) was founded
• 1992: Takeover of Fokker
• 1997: Takeover of Ford's commercial vehicle production
In addition, the group's administration changed locations as well as their
external appearance. In 1990, they moved to Stuttgart-Möhringen.
• In 1966, Maybach became a subsidiary of the Daimler Benz AG.

The "Maybach-Mercedes-Benz Motorenbau GmbH" was founded.
• In 1978, the Daimler Benz AG in cooperation with Bosch developed the
antilock brake system.
• In 1981, seat belts, emergency tensioning retractors and airbags were
introduced.
Möhringen in 1990 Möhringen in 1920
01/08 Daimler AG 5
• 1998: Fusion with Chrysler. • May 14, 2007 Announcement of the separation from Chrysler
Under then Chairperson and Chief Executive, Prof. Dr. Jürgen • August 03, 2007 Sale of the majority to Chrysler completed.
Schrempp, a reorientation to the core business of the group took place:
The manufacturing of vehicles. • October 04, 2007 DaimlerChrysler renamed Daimler AG.
• 2000: Takeover of Western Star Trucks.
• 2000: DASA merged with French and Spanish groups of companies to
become "EADS" (European Aeronautic Defense and Space Company).
Today, Daimler AG holds approx. 22.5 % of EADS

shares.
• From 2001 – 2004, AEG-AG was taken over to become Bombardier
Transportation in several steps (AEG-Schienenfahrzeug GmbH, Adtranz
GmbH).
Since 2004, the company belongs to the Elektrolux group.
• In 2002, the former Debis was dissolved as a result of partial sales to
the Deutsche Telekom. This branch of the company is now called Daim-
ler AG Financial Service (DC-Bank, Leasing, Charterway and also Toll
Collect with Daimler holding a share of 45 %).
• 01.01.2006: Dr. Dieter Zetsche becomes Chief Executive Officer.
01/08 Daimler AG 6
Daimler AG, Plants in Germany
Sindelfingen Production since 1915 Hamburg Production (since 1970)
approx. 41,000 C-Class sedan, C-Class sports coupe, approx. 2700 Formerly Hanomag - Henschel
employees E-Class sedan, E-Class wagon, employees Axles, steering columns, pedal assemblies,
S-Class, CL coupe, CLS and Maybach shift mechanisms, parking brakes,
molded parts.
Stuttgart- Production (since 1904) Wörth Production (since 1965)
Untertürkheim in 7 plant areas approx. 9500 World's largest commercial vehicle assembly plant
approx. 21,000 Engines, axles and transmissions employees Actros, Axor, Atego, Econic, Unimog
employees for Mercedes-Benz passenger cars and vans
Rastatt Production Gaggenau Production
approx. 6500 Latest manufacturing plant approx. 4500 Commercial vehicle axles and transmissions
employees for A-Class and B-Class employees
Germersheim Central replacement parts store Mannheim Production
(GLC = Global Logistics Center) approx. 8700 Commercial vehicle engines including foundry
employees Urban buses and vehicle shell for touring coaches
(EVOBus)
Conversion to natural gas vehicles and fuel cells
Bremen Production (since 1969) Düsseldorf Production
approx. 15,000 C-Class sedan, C-Class wagon, approx. 5000 Vans: Sprinter and VW LT, including separate parts for
employees SL roadster, SLK roadster employees export to the USA
High portion of export production
Kassel Production (since 1978)
approx. 3000 Commercial vehicle axles
employees
01/08 Daimler AG 7
Daimler AG, Plants in Germany
Berlin- Production (since 1902) Ludwigsfelde Production (since 1936)
Marienfelde Twelve-cylinder gasoline engines, approx. 1500 Vans: Vario and Sprinter
approx. 3000 eight-cylinder and six-cylinder diesel engines, smart employees
employees engines
Ulm/Neu-Ulm Production
Components and parts for MB passenger cars and approx. 3700 EVO-Bus touring coaches
smart, employees
reconditioned engines and parts for MB passenger cars
and MB vans,
new engines in small and special series
AMG GmbH Production Smart-BRABUS Production
Affalterbach, High-performance passenger car engines, sporty high- GmbH, Bottrop Smart-BRABUS, exclusive vehicles
performance vehicles, special equipment, accessories
approx. 750
employees
01/08 Daimler AG 8
Daimler AG, international plants
USA Production India Production
- Tuscaloosa M-Class, R-Class - Pune C-Class, E-Class and S-Class
approx. 2000 approx. 300
employees employees
USA Central Turkey Production
- Portland development and production of Freightliner - Aksaray and Trucks, Unimog, buses and major assemblies
approx. 12,800 Davutpasa
employees approx. 2000
employees
Brazil Production France Production
- Juiz de Fora A-Class and C-Class - Hambach Smartville (city coupe, convertible, roadster)
employees employees
Brazil Production France Conversion
- Sao Bernardo Trucks, buses and major assemblies - Molsheim Trucks into special commercial vehicles
approx. 11,000 approx. 400
employees employees
Argentina Production Spain Production
- Buenos Aires Sprinter and buses - Vitoria Vito/Viano
employees employees
South Africa Production
- East London Right-hand drive vehicles C-Class
and Pretoria Commercial vehicles (MB 800 and L200 )
approx. 4500
employees
The information in the tables is not exhaustive and is not updated. The information has been last revised 10/2007.
Special attention should be paid to the future development in the Beijing (China) plant. No information was available at the time the documents were prepared.
01/08 Daimler AG 9

01/08 Daimler AG 10
The Technical Milestones
Mercedes and Mercedes-Benz technologies that made history

Introduc- Introduc-
Technology Technology
tion tion
1900 Mercedes 35 hp: First modern car with all-alloy engine, con- 1931 Mercedes-Benz 170 with front and rear "swing axles" (inde-
trolled intake valves, honeycomb radiator, coil clutch, pressed- pendent wheel suspension).
steel frame, low center of gravity, impact-free steering and 1933 World's first double wishbone front axle with coil springs as
water-cooled brakes. used for the first time in Mercedes-Benz 380.
1903 New high-performance engines with controlled overhead intake 1936 Mercedes-Benz 260 D: First series production passenger car
valves in Mercedes-Simplex 18/22 hp and Mercedes-Simplex with a diesel engine.
60 hp. 1939 First test vehicle with stable protective side molding, ex-
tremely stiff floor, three-piece steering column.
1906 Six-cylinder race car engine with turned steel cylinders and 1947 Prototype "Terra Cruiser" with safety steering wheel.
overhead camshaft, driven by a vertical shaft: Model for aircraft
engines and high-performance automotive engines. 1949 Patented conical safety pin-door lock prevents the doors from
opening in an accident.
1911 Mercedes 37/90 hp with three-valve technology and dual igni- 1951 Patented safety-enhanced vehicle body with passenger cell in
tion. fatigue strength and defined front and rear crumple zones.
1914 Mercedes 28/95 hp: Series production of a six-cylinder engine 1954 Single-joint swing axle in Mercedes-Benz 22.
with turned steel cylinders and overhead camshaft, driven by a Mercedes-Benz 300 SL: Worldwide first use of gasoline injec-
vertical shaft. tion in a series production passenger car with four-stroke
engine.
1923 Mercedes 6/25/40 hp and 10/40/65 hp:
1958 Wedge-pin door lock with two safety catches.
First series production passenger cars with a compressor motor.
1927 Mercedes-Benz L 5: First six-cylinder diesel truck.

01/08 The Technical Milestones 11
Introduc- Introduc-
tion tion
1959 First impact and rollover tests. 1971 Start of ESV program (ESV = Experimental Safety Vehicle) –
First safety-enhanced vehicle bodies worldwide with integrated ESV test vehicles with 3-point automatic seat belts, belt
crumple zones in the Mercedes-Benz "tail fin". force limiter, emergency tensioning retractor and first airbags
for driver and front passenger.
Passenger car models with smooth interior equipment.
Mercedes-Benz 350 SL with seat belt buckle attachment on
1961 All Mercedes-Benz vehicles come standard with anchor points seat frame, four-spoke safety steering wheel and side win-
for the front seat belts. dows and taillamps where dirt cannot easily accumulate.
Dual-circuit hydraulic brake system with disk brakes on front 1973 Standard three-point seat belts and front head restraints.
and rear wheels on Mercedes-Benz 300 SE. First child seat modules.
First diagonal shoulder belt. First Mercedes-Benz offset crash test.
1963 Mercedes-Benz 230 SL: First sports car with safety-enhanced 1974 Mercedes-Benz 240 D 3.0: First series production passenger
vehicle body. car with a five-cylinder engine.
1966 New safety steering system with corrugated tube in model
Development of a schematic for systematic safety research. The 1976
series W 123.
concepts "active and passive safety" are created.
1977 Mercedes-Benz 300 SD: First series production diesel pas-
senger car with turbocharging.
1967 Safety steering system, consisting of a telescopic steering
column and a steering wheel with impact absorber, standard in 1978 Market launch of the antilock brake system ABS:
all models. World premier in the Mercedes-Benz S-Class model series
116.
1968 Introduction of the Mercedes-Benz safety head restraint. Offset crash with a 40 %front overlap becomes
First three-point static belt . part of the stringent internal test criteria.
First tests with airbag systems.
1979 All Mercedes-Benz vehicles come standard with three-point
seat belts on the outer seats.
1969 Official start of the Mercedes-Benz accident research with ana-
lysis of traffic accidents. First front seat belt height adjustment in the S-Class.

Introduc- Introduc-
tion tion
1979 New S-Class model series W 126 is the first passenger car world- 1993 Standard catalytic converter for all Mercedes-Benz diesel pas-
wide to be designed for an offset crash due to the fork retainer senger cars.
structure of the front end.
1994 First rear end crash against a deformable barrier.
1981 First driver airbag and emergency tensioning retractor worldwide in NECAR (New Electric Car): First fuel cell test vehicle by Mer-
the S-Class. cedes-Benz.
1982 Independent multilink rear suspension as a world novelty in the 1995 Series introduction of the driver safety system "Electronic Stabil-
Mercedes-Benz compact class (W 201). ity Program" (ESP) in the S 600 coupe.
1984 All Mercedes-Benz vehicles come with front emergency tensioning First emergency tensioning retractor with integrated belt force
retractors. limiter worldwide.
1985 For the first time, ASD (automatic locking differential), ASR (accel-
eration skid control) and 4MATIC (shift-on-the-fly four wheel drive).
1996 Coupe study for F 200 with "Drive-by-Wire" and "Keyless-Go"
technology.
1986 Controlled three-way catalytic converter comes standard in all
Series introduction of the Brake Assist System (BAS) as a global
passenger cars with gasoline engine.
innovation.
1988 First front passenger airbag as special equipment in the S-Class. 1997 New V6 and V8 engines with three-valve technology and dual
ignition.
1989 First seats with integrated seat belts, first automatically extending
roll bar and first draft stop in the Mercedes-Benz SL roadster. S-Class comes standard with sidebags.
Automatic height adjustment of rear seat belts in model series 124. A-Class with sandwich floor and an engine that moves under-
neath the body in the event of a frontal impact.
New passenger car diesel engines with common rail diesel injec-
tion (CDI).
1992 All Mercedes-Benz vehicles come standard with driver airbag and NECAR 3 (based on A-Class): First fuel cell test vehicle world-
ABS. wide with on-board hydrogen generation.
Standard front passenger airbag in the S-Class.
First offset crash against a deformable barrier.
1993 First integrated child seat for C-Class as a special equipment.
First four-valve diesel engines for C-Class and E-Class.

Introduc- Introduc-
tion tion
1998 First use of windowbags as a special equipment in the E-Class. 2002 New 1.8 liter four-cylinder engine with direct injection - is the
S-Class with a total of 30 new technical developments e.g. front new benchmark when it comes to fuel consumption, torque
passenger airbag with two-stage gas generator, emergency characteristics, power characteristics, lightweight design and
tensioning retractors and belt force limiters in the rear, auto- smooth operation.
matic child seat recognition (AKSE), air suspension with adap- Setra Top Class 400 with ESP, the first time in a touring
tive damping system (AIRmatic), COMAND operating and display coach.
system, etc.
The safety system PRE-SAFE® in the S-Class prepares pas-
sengers in the event of emergency braking or in critical driv-
1999 Mercedes-Benz CL coupe: First series production vehicle world- ing situations for an accident to the extent possible.
wide with active suspension Active Body Control (ABC). The front passenger weight sensing system that was used for
All Mercedes-Benz vehicles come standard with Electronic the first time makes it possible to deploy the airbag depend-
Stability Program. ing on the situation.
First series production breakpoint of the autonomous intelligent Electricity from solar cells in the glass roof of the E-Class
cruise control Distronic. make stationary ventilation possible to cool the interior com-
CSO [ZAS] – cylinder shutoff in S 600 and CL 600. partment.
2000 Most powerful passenger car diesel engine in S 400 CDI world- 2003 Development of synthetic diesel fuel in cooperation with
wide. Volkswagen and Choren. "Biotrol" is made out of the organic
Ceramic brake (C-BRAKE) used for the first time in CL 55 AMG matter of wood scraps.
F1 Limited Edition. SCR technology is adopted in production planning.
Development and use of Lane Assistant system and comfort
systems ( PROTECTOR). Mercedes-Benz is the first automotive brand worldwide to
offer a combination of particulate filter and EU-4 emissions
2001 First series production breakpoint worldwide for the electrohy- standard for diesel passenger cars.
draulic brake Sensotronic Brake Control (SBC™) in SL (R 230).
Innovative head/thorax sidebags for the roadster in the doors.
First Citaro with fuel cell drive.

Introduc- Introduc-
tion tion
2005 New V6 and V8 engines with four-valve technology. 2006 Gasoline engine with spray-guided direct injection in Mer-
The new Mercedes-Benz S-Class, the first car worldwide with an cedes-Benz CLS 350 CGI.
ecology certificate. ADAPTIVE BRAKE provides assistance function for hill starts
Introduction of the SCR technology for commercial vehicles in and urban traffic.
order to meet the exhaust emissions standards of Euro 4 and Intelligent Light System, a headlamp system offering five light
comply with Euro 5 in advance. situations that switch on depending on the driving and
S-Class W 221 with a new safety philosophy PRO-SAFE™, con- weather situation (cornering illumination, country light, mo-
sisting of the elements PERFORM-SAFE (active safety, driving torway lights, curve illumination and extended fog light func-
safety, perceptual and stress-reducing safety), PRE-SAFE® tion).
(preventive safety systems that alleviate the consequences of Rain sensor with a second sensitivity stage.
an accident through foresight), PASSIVE-SAFE (passive safety,
internal safety) and POST-SAFE (support systems with the pur- PRE-SAFE® brake – in the event of imminent danger of a
pose of preventing further damages after an accident). collision, the system performs an automatic partial braking
maneuver.
S-Class: Introduction of pulsating brake lights in the event of
emergency stops. Newly developed all-wheel drive 4MATIC for the Mercedes-
Benz S-Class.
Night view assistant in the S-Class. It operates with infrared
headlamps that illuminate a significantly larger area of the First series production passenger car with BLUETEC: Mer-
roadway when it is dark than the low beams. The extended night cedes-Benz E 320 BLUETEC comes on the market in the USA
view picture is shown on the display of the instrument cluster. in October 2006.
Particulate filters are installed as standard in diesel passenger
cars. The output of soot particles is reduced by 95 percent. 2007 ADVANCED AGILITY package: The tuning of shock absorber
and transmission can be changed at the push of a button.
AGILITY CONTROL package: A selective damping system
adjusts the shock absorber forces depending on the driving
situation.
The E 300 BLUETEC makes its debut on the European mar-
ket.

Overview of Light Vans
General note
The sales designation for vans (except Vaneo) consists of two connected The first row of numbers indicates the permissible gross vehicle weight in
number codes (e.g. 318). tons. The second number represents the output in horsepower.
Model designa- Weight class

Sales designation Model Designation Output in hp Engine model
tion t total weight
VANEO 1.6; VANEO 1.9;
414.7 plus 1,9 75 - 125 166.9.. / 668.9..
VANEO CDI; VANEO CDI 1.7
113; 114; 108 CDI;
638.0.. / 1.. 2.7 – 2.9 80 - 140 111.9.. / 611.9..
110 CDI; 112 CDI
VITO / V Class
V 200; V 230; V 280; 111.9.. / 104.900
638.2.. 80 -
V200 CDI; V 220 CDI 611.9..
119; 126;
112.9.. /
109 CDI; 111 CDI; 639. 6.. / 7.. 2,7 – 2,9 90 -220
646.9.. /642.990
VITO / VIANO 115 CDI; 120 CDI
3.0; 3.5 272.9..
639.71. / 81. 2,7 – 2,9 116 - 258
2.0 CDI; 2.2 CDI 646.9.. /642.990
224 901. ... 272.9..
3,0 – 3,2 88 - 258
209 CDI – 218 CDI 902. ... 642.9..
314 272.9..
903. ... 3.5 88 - 258
309 CDI – 318 CDI 642.9..
SPRINTER
424 272.9..
904. ... 4,6 109 - 258
411 CDI – 418 CDI 642.9..
524 272.9..
905.6.. 6 88 - 258
511 CDI – 518 CDI 642.9..
The table is not necessarily complete!
01/08 Overview of Light Vans 16
Sprinter panel van (901 – 906) Sprinter platform vehicle (901 – 906)
Vito/Viano (639.6 - 8) Vaneo (414.7)
01/08 Overview of Light Vans 17

Overview of Commercial Vehicles (Excerpt)
Itemization of the chassis numbers Mercedes-Benz commercial vehicles

e.g. WDB 930 031 1K 123456
Chassis number (production progress)
Steering 1 = Left-hand drive vehicle;
2 = Right-hand drive vehicle
Manufacturing
plant K,L = Wörth
0, P, R = Düsseldorf
N = Ludwigsfelde
Model designation Atego (970 - 974) Atego 4x4 (930 - 934)
Vehicle model
World manufacturer code
Axor (940 - 944) Axor (940 - 944)
The table is not necessarily complete.
01/08 Overview of Commercial Vehicles (excerpt) 18

Mercedes-Benz commercial vehicles
Actros (930 - 934) Actros (930 - 934) Econic (957.0..)
Other commercial vehicles in the Daimler group of companies
Mitsubishi Canter Travego Western Star Sterling Trucks

Mercedes-Benz buses
Citaro Capa-City Travego Sprinter Travel
Other buses in the Daimler group of companies
Thomas Built school bus Thomas Built school bus Orion bus



Vehicle Versions and Designations
Vehicle versions
The various commercial vehicle versions are denoted by a letter and num-
ber combination and have the following meaning:
A All-wheel drive platform vehicle
AK All-wheel drive dumper vehicle
AS All-wheel drive semitrailer tractor vehicle
AF All-wheel drive fire-fighting vehicle
F Fire-fighting vehicle
B Concrete mixer
K Dumper vehicle
KO Municipal vehicle
L Air spring platform vehicle
LK Air spring dumper vehicle
LKO Air spring municipal vehicle
LS Air spring semitrailer tractor vehicle
KK Crane dumper vehicle
S Semitrailer tractor vehicle
nR Low frame
nRA Low frame, car transporter
nRA Low frame, Lowliner
DNA Dual-tired trailing axle
VLA Leading axle
6 x 2 Three-axle vehicle
Platform vehicles or chassis are an exception. They are not assigned any
designation.
01/08 Vehicle Versions and Designations 22

Wheel configurations
The axle and drive configuration of a vehicle is recognizable from the wheel
configuration. This contains:
• Number of installed axles
• Number of driven axles
• Number of steerable axles
• Type of axles
Meaning
4x2 2-axle vehicle with one driven rear axle
4x4 2-axle vehicle with all-wheel drive
6x4 3-axle vehicle with two driven rear axles
6x6 3-axle vehicle with all-wheel drive
6 x 2 DNA 3-axle vehicle with one driven rear axle and one dual-tired
trailing axle
6 x 2/4 VLA 3-axle vehicle with one steered leading axle and one driven
rear axle
6 x 2/2 VLA 3-axle vehicle with one rigid leading axle and one driven rear
axle
8 x 4/4 4-axle vehicle with two driven rear axles and two steered
front axles
8 x 6/4 4-axle vehicle with two driven rear axles and two steered
front axles, the first front axle being driven
8 x 8/4 4-axle vehicle with all-wheel drive and two steered front
axles

Model Designation Model designation
The model designation for Mercedes-Benz vehicles is composed of a com- Based on the design, Mercedes-Benz commercial vehicles are subdivided
bination of numbers and letters. into different assemblies using a three-digit number. The first two digits
The numbers provide information about the permissible gross vehicle indicate the vehicle model, the third digit provides information about the
weight and the engine power. The first two numbers refer to the permissi- vehicle model and the type of body
ble gross vehicle weight, the last two to the engine's horsepower, the last
digit of this being omitted. Examples of vehicle models
If only a multi-digit number is specified, this is a cab-over-engine platform 970 – 974: ATEGO2
vehicle or chassis. 940 – 944: AXOR2
The letters provide information about the construction of the vehicle mo-
del. 930 – 934: ACTROS2
957: ECONIC
Example:
Body types using Actros2 as example
Model: 2655 L 6 x 2
930 = Actros2 with platform
26 Permissible gross vehicle weight in tons
932 = Actros2 with dumper
55 Engine power in horsepower (= x 10)
L Air suspension 933 = Actros2 concrete mixer
6x2 Axle designation 934 = Actros2 semitrailer tractor
6 Number of wheels or wheel pairs
x2 Number of driven wheels or wheel pairs

Cab
Mercedes-Benz cabs were designed specifically for the requirements of the

driver and front passenger. Particular importance was attached to driving,
operating and climate comfort and the transport tasks.
All cab versions are designed based on the latest considerations regarding
ergonomics and safety.
The layout of the modular cockpit with the instrument system complies
with requests made by drivers.
Located right in the visual field is the new large-sized instrument cluster. Its
"light trap" prevents reflections, improving readability considerably.
The four-spoke multifunction steering wheel (optionally available with
airbag) now has conveniently placed function keys with multiple assign-
ment as found in Mercedes-Benz passenger cars. The steering wheel con-
trol buttons permit convenient operation of communication devices, such
as radio and telephone as well as the driver information system (FIS).
With its harmonized colors and soft-touch surfaces the cockpit provides
large, non-slip tray surfaces on which a coffee maker or a TV can be placed
during break periods, for example. The well thought-out lighting concept
also creates a cozy atmosphere.
Different cockpit versions are available for distribution and long-haul appli-
cations.
01/08 Cab 25
S-cab
The spacious S-cab is designed for the needs of the driver and front pas-
senger for distribution, short-distance and construction site applications.
The S-cab offers numerous tray surfaces (doors, roof, rear panel). The short
dimensions of the cab provide optimal use of space for bodies.
The S-cab is optionally available with a rear panel that has been moved 180
mm to the rear, providing the driver with greater freedom of movement and
additional storage trays.
The movable steps on the driver and passenger sides are designed specifi-
cally for vehicle use on construction sites and rough terrain. They are
mounted on a swing pivot. When they come into contact with obstacles,
the steps are moved in the opposite direction, parallel to the longitudinal
axis of the vehicle.
M-cab
The comfortable M-cab with the spacious interior is designed for the needs
of the driver and front passenger for distribution and national long-distance
haulage. It offers plenty of space and tray surfaces (sidewalls, roof, doors,
rear panel). It can optionally also be equipped with a bunk.
01/08 Cab 26
L-cab
The L cab is designed specifically for the needs and comfort of the driver
and front passenger for long-distance haulage and offers plenty of room
and plenty of stowage space (side walls, doors, roof, rear panel).
The L cab is available in different heights for different transport tasks. The
combination of driving and living, which provides a larger interior thanks to
an extended rear panel and creates space because of a wider lower bed.
The L cab is also available with a straight rear panel.
Megaspace cab
The comfortable Megaspace cab offers an extremely generous interior and
a continuous cab floor. It is designed specifically for the needs of the driver
and front passenger for international long-distance haulage. The Megas-
pace cab has been designed based on the latest considerations for ergo-
nomics and safety and has an extremely large provision of space and stow-
age areas.
Single cab - Megaspace and L-cab
The single cab is designed specifically for the needs and comfort of the
single driver for international long-distance haulage. It offers plenty of
space and stowage areas (sidewalls, doors, roof, rear panel). An easy chair
is provided at the rear panel instead of the front passenger seat.
The Megaspace cab and the single cab are only available for the ACTROS
left-hand drive vehicle.
01/08 Cab 27
Crewcab (1 + 5 people) L and M cab with particularly low roof
With an internal height of 1400 mm this roof shape is tailored to bodies
The cab with crewcab is only available for the ATEGO and is designed for
that project above the cab, such as fire-fighting turntable ladders, concrete
applications requiring a large capacity for transporting people (e.g. removal
pumps and lifting platforms.
companies, firefighting crew vehicles, etc.).
It is based on the S-cab of the ATEGO. L cab with particularly low roof DD3
This roof version satisfies the particular requirements of a car transporter.
L cab with low roof - ACTROS As a special version it has an internal height of 1400 mm and also a cab
This roof version offers a roof that is 400 mm lower and has an internal that has been lowered by 90 mm.
height of 1560 mm. This makes it particularly well-suited
for refrigerated vehicles, but it still retains the tilting facility.
Econic
With the ECONIC cab, numerous customer requests were fulfilled that con-
tribute to making day-to-day work easier through specialized detail solu-
tions. The cab was lowered as close to the street as possible, so that fre-
quent entering and exiting is easy to manage. The driver and front
passenger doors are provided with internal entrance boxes.
The front passenger door is designed as a folding door specifically for
waste disposal vehicles.
The modular front passenger seat design means that the ECONIC is avail-
able with up to three individual, comfortable front passenger seats.
Fitted on the passenger side on the dashboard is a grab handle which
provides additional means for holding on when getting in and when driving.
The cab is available as a high or low version for the variety of transport
tasks. The cab floor is flat throughout and corresponds to a height of
800 mm. The internal heights of the two versions are 1485 mm and
1935 mm, respectively.
01/08 Cab 28
Cab lock
All cabs have an automatic cab release. The locks open as soon as the cab
has been pumped forward using the mechanically hydraulic tilting pump
located in the right entryway steps. When tilting the cab back, the locks are
closed automatically. The "Cab lock" indicator lamp in the dashboard tells
the driver whether the cab is fully locked.
The indicator lamp goes out after approx. 8 seconds or if the engine is
started.
The cab mounting is designed so that the cab can be tilted up to 70° in the
S, M, L and Megaspace versions.
Tilt the cab.
Before the cab is tilted, the engine must be shut off, the transmission
gearshift lever must be placed in neutral and the area in front of the gear-
shift lever and in front of the cab must be kept clear for safety reasons.
On vehicles with Telligent® gearshift, shift transmission to neutral.
The cab must always be tilted as far as the end position. If the cab has to
be held in an intermediate position, a secure support must be used.
The mechanical/hydraulic tilting pump is located
• behind the fender of the right front wheel on the ATEGO with L cab and
crewcab as well as for all cab versions of the AXOR
• On the right in the mechanical entryway steps on the ACTROS
The Atego S-cab is fitted as standard with a spring-based tilting mechanism
and can be tilted by hand after releasing the cab. The hydraulic tilting
mechanism is available as special equipment, however.
01/08 Cab 29
Note Long-distance haulage vehicle cockpit
On the Actros the maintenance flap must be opened before tilting the cab. The long-distance cockpit is designed specifically for the needs of medium-
distance and long-distance haulage. In its design and functionality it corre-
Cockpit (example of ACTROS) sponds to the Comfort cockpit but has more stowage trays and stowage
The layout of the modular cockpit with the instrument system complies spaces.
with requests made by drivers.
The new large-sized instrument cluster is located right in the visual field. Its
"light trap" prevents reflections, improving readability considerably.
The four-spoke multifunction steering wheel (optionally available with
airbag) now - like Mercedes-Benz passenger cars - has conveniently placed
function keys with multiple assignment. The thumb-operated buttons per-
mit convenient operation of communication devices, such as radio and
telephone as well as the driver information system (FIS).
With its harmonized colors and soft-touch surfaces the cockpit provides
large, non-slip tray surfaces on which a coffee maker or a TV can be placed
during break periods, for example. The well thought-out lighting concept
also creates a cozy atmosphere.
Distributor vehicle cockpit
The distributor vehicle cockpit is designed specifically for the needs of
delivery vehicle operators and provides good climb-through access to the
passenger side. It is driver oriented, has ergonomic controls and is de-
signed to be functional.
Comfort cockpit
The Comfort cockpit is designed specifically for the needs of medium-
distance and long-distance haulage. In its design and functionality it corre-
sponds to the distributor vehicle cockpit, but has additional stowage trays
and stowage spaces.
01/08 Cab 30
Overview of Gasoline Engines
Displacement Rated output Rated torque

Engine Charging
cm³ in kilowatt in Nm Used in
M 111 2295 105 215 No Sprinter 901

3199 140 270 No Vito 639
M 112
3724 190 345 No Vito 639
M272 3498 190 345 No Vito 639, Sprinter 906
01/08 Overview of Gasoline Engines 31

Engine 112
Engine 112 is a 90° V6 gasoline engine. The V6 engines are characterized
by:
• Low weight (approx. 160 kg),
• low fuel consumption,
• fewer pollutants in the exhaust,
• smoother operation.
A balance shaft, which rotates in the opposite direction to the crankshaft at
the crankshaft rotational speed, is used to compensate for the free forces
(rough operation) inherent in a 90° V6 gasoline engine. The smooth opera-
tion of a 6-cylinder inline engine is thus achieved.
The exhaust gas emissions conform to current limits and also have the
necessary potential for meeting future limits.
This is achieved, for example, by:
• Three-valve technology,
• two spark plugs per cylinder,
• phase-shifted alternating dual ignition,
• increased exhaust gas recirculation compatibility,
• air gap-insulated exhaust manifolds with new inner pipe technology,
• catalytic converters based on terminal technology.

M 272
The M 272 is a new V6 engine which is used in the Vito 639 and in the
Sprinter 906.
It has an output spectrum of 150 – 200 kW and a rated torque of 245 –
350 Nm.
The most important features of this engine are:
• Four-valve technology with variable, continuous camshaft adjustment

on the intake and exhaust side.
• Valve actuation via roller-type cam followers.
• Variable intake manifold with variable length intake manifold switchover
flaps and tumble flaps.
• Reduced moved masses due to lightweight crank assembly (pistons and
conrods)
• Reduction in fuel consumption by optimizing combustion



Overview of diesel engines
Displace-
Rated output Rated torque
Engine ment Charging Used in
kW at rpm Nm at rpm
cm³
OM 642 2987 140 at 4000 400 at 1400 - 3200 Turbo Sprinter 318 CDI
2148 80 at 3800 290 at 1600 - 2400 Turbo VIANO 2.0 CDI, Vito 111 CDI
OM 646
2148 110 at 4200 340 at 1800 - 2600 Turbo Vito 115 CDI
OM 647 2688 130 at 4200 400 at 1800 - 2600 Turbo Sprinter 313 CDI
OM 648 2987 140 at 4000 400 at 1400 - 3200 Turbo Sprinter 318 CD
4250 95 at 2200 500 at 1200 - 1600 Turbo Vario: 613D, 813D,
Atego: 713, 813
4250 115 at 2200 610 at 1200 - 1600 Turbo Vario: 616D, 816D
OM 904 LA
ATEGO: 816, 916, 1016, 1216
4250 130 at 2200 675 at 1200 - 1600 Turbo Vario: 618D, 818D
ATEGO: 818, 918. 1018, 1218, 1318, 1518
OM 924 LA 4800 160 at 2200 810 at 1200 - 1600 Turbo Atego: 922822, 1022, 1222, 1322,1522
01/08 Overview of Diesel Engines 35

Displace-
Rated output Rated torque
Engine ment Charging Used in
kW at rpm Nm at rpm
cm³
6370 175 at 2200 850 at 1200 - 1600 Turbo Atego: 824, 924, 1024, 1224, 1324, 1524
Axor: 1824
6370 188 at 2200 970 at 1200 - 1600 Turbo Atego: 926, 1226, 1326, 1526
OM 906 LA
Axor: 1826
6370 210 at 2200 1120 at 1200 - 1600 Turbo Atego: 1229, 1329, 1529
Axor: 1829, 2529, 2629
OM926 LA 7200 240 at 2200 1300 at 1200 - 1600 Turbo Axor: 1833, 2533, 2633
11970 265 at 1900 1850 at 1100 Turbo Axor: 1836, 2536, 2636, 3236, 3336, 4136
OM 457 LA 11970 295 at 1900 2000 at 1100 Turbo Axor: 1840, 2540, 2640, 3240, 3340, 4140
11970 315 at 1900 2100 at 1100 Turbo Axor: 1843, 2543, 2643, 3243, 3343, 4143
11946 235 at 1800 1650 at 1080 Turbo Actros: 1832, 2032, 2532, 2632, 3232, 3332
11946 300 at 1800 2000 at 1080 Turbo Actros: 1841, 2041, 2541, 2641, 3241, 3341, 4141
OM 501 LA
OM502 LA 15928 405 at 1800 2600 at 1080 Turbo Actros: 1855, 2055, 2555, 2655, 3355
15928 440 at 1800 2800 at 1080 Turbo Actros: 1860, 2560, 2660, 3360

OM 646 & 647
Engines 646 and 647 appeared at the market launch of the E-Class (model
211) and are also installed in the Vito and Sprinter, among others. The
output and torque had been boosted compared with their predecessors
M611 and M612.
This increase was achieved by:
• Increasing the cylinder pressure
• Optimized gas cycle
• electric actuation of the turbochargers and
• increase of the system pressure of the CDI system to 1600 bar.
The two counter-rotating balance shafts contribute to a considerable im-
provement in the smooth running of the 4-cylinder engine. They bring about
a clear reduction in noise emissions and vibrations.
The housing, in which the shafts are mounted, is bolted to the underside of
the crankcase.

OM 642
The OM 642 is a new 6-cylinder V-engine and replaces the previous engine
model series OM 647 and OM 648.
This engine is installed in a series of vehicle models, since it has an output
spectrum of 140 kW to 165 kW and a rated torque of 400 Nm to 510 Nm.
The most important new features are:
• Third generation common rail diesel injection with piezo injectors
• Aluminum V6 crankcase
• Valve actuation via roller-type cam followers
• Up to two preinjections and post injections
• Turbocharger with optimized airflow
• Water-cooled heat exchanger for exhaust gas recirculation
• Improved venting system with centrifugal separator
• Instant start glow system
• Compliance with the EU4 exhaust emissions standards (with and with-
out diesel particulate filter)
Note
The OM 642 engine is described in the Introduction into Service Manual
"Introduction of the new V-engine generation 6-cylinder OM642". In addi-
tion, a system description "Common rail diesel injection CDI 4" is available.

Engine model series 900
The 900 series engines include The 900 series engines are exceptionally low-maintenance due to the long
• 4-cylinder engines OM 904 LA & 924 LA, service intervals:
• 6-cylinder engines 906 LA & 926 LA • Long-distance haulage: approx. every 100,000 km
and are designed for lightweight and medium-heavy commercial vehicles. • Short-distance haulage: approx. every 60,000 km
The basic features are: • Heavy duty operation (off-road): approx. every 30.000 km
Oil and fuel filter is also quickly and easily exchangeable as part of the
• Inline engine with shared cylinder head
routine oil change.
• Cylinder crankcase with cylinder barrels
• 3-valve technology
• Compact construction of cylinder crankcase thanks to the integration
of the oil cooler, unit pumps, as well as coolant, oil, and fuel ducts.
• High pressure direct injection with unit pumps, Pump-Line-Nozzle (PLD)
system, with peak pressures of up to 2200 bar
• Electronic engine management with engine-mounted electronics and
extensive engine protection functions
• Direct injection with centrally located 9-hole injection nozzle
• Engine brake: Constant throttle and exhaust flap
• Turbocharger with charge air cooling
• Engine oil and fuel filter are located at the front end, permitting easy
maintenance
• Operation with FAME (biodiesel) possible, but the engine oil change
intervals must be halved
• Engine power take-off to rear
• Preinstallation for retrofitting Frigoblock
• Compliance with emissions standard Euro 4 and pre-compliance with
emissions standard Euro 5

OM 457 LA
OM 457 LA is a 6-cylinder inline engine with 4-valve technology and is
OM 457 LA is designed for long maintenance intervals. Under correspond-
installed in the Axor in three different power stages.
ing conditions in long-distance haulage these can be up to 120,000 km.
The basic features are:
• Inline engine with 6 individual cylinder heads
• Cylinder crankcase with wet cylinder liners
• High-pressure direct injection with unit pumps, Pump-Line-Nozzle (PLD)
• Engine brake: Constant throttle and exhaust flap or turbobrake
maintenance
• Additional fuel filter (Racor filter)
• Viscous fan clutch or electromagnetic fan clutch (Linnig) and high-
speed fan drive for more powerful engine versions
• Compliance with emissions standard Euro 4 and pre-compliance with
emissions standard Euro 5

Engine model series 500
The 500 series engines include • Compliance with emissions standard Euro 4 and pre-compliance with
• 6-cylinder engines OM 501 LA with engine power from 235 – 350 kW emissions standard Euro 5
• 8-cylinder engines OM 501 LA with engine power from 375 – 440 kW The engine series is designed for long maintenance intervals. Under corre-
and are only installed in the Actros. sponding conditions in long-distance haulage these can be up to
150,000 km.
The basic features are:
• V engine with 6 or 8 individual cylinder heads
• Cylinder crankcase with wet cylinder liners
• High-pressure direct injection with unit pumps, Pump-Line-Nozzle (PLD)
• Engine brake: Constant throttle and exhaust flap or turbobrake
maintenance
• Additional fuel filter (Racor filter)
• Viscous fan clutch or Visctronic electromagnetic fan control and high-
speed fan drive for more powerful engine versions

Engine oil replacement interval up to 150,000 km Fan drive
For the Euro 4/5 engines in model series 500 the engine oil replacement The fan is driven at a speed that is faster than the engine speed due to the
interval can be extended to 150,000 km without any restrictions with high-speed fan drive.
regard to use under particular road, off-road or climatic conditions. The To this end, the fan is driven by means of a separate belt.
following technical measures are required for this on the engines:
As the fan's belt pulley has a smaller diameter than the belt pulley at the
crankshaft, a step-up ratio is achieved and the fan's cooling output is in-
OM 501 LA creased.
• Enlarged oil pan
The high-speed fan drive is predominantly recommended for vehicles in hot
countries or for vehicles with a high tractor trailer combined gross weight
OM 501 LA and OM 502 LA (e.g. heavy-duty transport).
• Installation of an oil centrifuge in the engine oil circuit above the oil
filter. The oil centrifuge is a disposable component and is replaced at
every oil change
• Installation of a structurally modified oil filter cartridge with filter sur-
face that is unchanged compared with the standard filter
• Modified oil cooler with enlarged cooling surface and increased cooling
output

BlueTec - diesel technology
The VARIO, ATEGO, AXOR and ACTROS commercial vehicle versions are equip-
ped with "BlueTec diesel technology" and comply with the Euro 4 standard
in force since October 2006, and they already comply with the Euro 5
standard that will be valid from October 2009. In contrast to the Euro 3
standard, the pollutant content of the exhaust gases is up to 80 % lower.
Using the BlueTec diesel technology it was possible to optimize engine
management, permitting better engine performance with greater fuel eco-
nomy.
The BlueTec diesel technology is active as soon as the SCR catalytic con-
verter has reached its operating temperature.
Function:
The pump module draws the AdBlue out of the AdBlue tank and pumps it to
the metering device via a heated supply line. In the metering device the
exact quantity of AdBlue is supplied via the metering valve to a continuous
air flow, mixed with this to form an aerosol, and delivered to the exhaust
flow via a nozzle at the valve fitting.
1 AdBlue tank
In the hot exhaust flow the AdBlue decomposes into ammonia (NH3) and 2 AdBlue pump module
carbon dioxide (CO2). Together with the nitrogen oxides this forms nitrogen 3 AdBlue metering device
(N2) and water (H2O) in the SCR catalytic converter. 4 Muffler with catalytic converter
In order to defrost the AdBlue after a cold start or to prevent it from freez- 5 Check valve
ing while driving, the entire AdBlue circuit is heated using coolant. The 6 Pressure limiting valve with vent
AdBlue lines are bundled with coolant lines. The pump module and the 7 Venting 3/2-way valve
AdBlue tank are flushed with coolant. 8 SCR tank heater solenoid valve
9 Nozzle
The AdBlue coolant circuit is controlled by the coolant valve dependent on 10 Bundled lines
the temperature. 11 Radiator
12 Engine
01/08 BlueTec Diesel Technology 43

Handling of AdBlue Risk of injury or poisoning
The following points must be observed when working with AdBlue: When the engine is warm, the AdBlue line system and connected system
components are under pressure. There is a risk of scalding caused by
• AdBlue contamination can be removed with water.
escaping hot AdBlue if the line system is opened suddenly.
• When AdBlue comes into contact with aluminum, a mild reaction oc-
curs, which can lead to an appearance change of the aluminum. In addition, there is a risk of skin irritation and eye damage if these body
parts come into contact with AdBlue.
• The contact of AdBlue with 1K paint (e.g. frame) can lead to an appear-
ance change
Rules of conduct
• Do not fill AdBlue into drinking containers.
• Wipe up any spilled AdBlue because wetted surfaces are very slippery.
Risk, health
AdBlue is an aqueous solution which, according to the applicable European
chemicals legislation, poses no special risk. It is not a hazardous sub-
stance, nor does it constitute hazardous goods under applicable transport
regulations.
If traces of the product come into contact with the skin while handling
AdBlue, it is sufficient to rinse these off with plenty of water. This practi-
cally eliminates any risk to health.



Range-change Transmission
In lightweight commercial vehicles a 6-speed manual transmission is ade- Splitter range

quate for an economic driving style, but in medium-heavy and heavy com-
The splitter group is connected upstream of all other transmission groups
mercial vehicles this can only be achieved with range-change transmis-
and is therefore also known as a front-mounted group. The splitter group
sions. 16-speed synchromesh transmissions are predominantly used as
makes different input speeds available to the main transmission.
range-change transmissions. In 2005 a new, fully automated range-change
transmission generation without synchronization was launched, the Mer-
The transmission is given a further constant speed gear with a slightly
cedes PowerShift transmission. This was primarily available for the AC-
faster gear ratio in the form of the splitter group. The countershaft can be
TROS2 as a 12- and 16-speed transmission, since August 2007 a semi-
driven either via the constant speed gear 1 (K1) or via the constant speed
trailer tractor version of the AXOR2 has been available with the gear 2 (K2). The designation of the constant speed gears is determined
G211-12K. In future the Mercedes PowerShift transmission will be in- from the transmission input.
stalled as standard in the ACTROS2, however the synchromesh transmis-
sions can still be ordered as special equipment. The countershaft is driven at different rotational speeds depending on
which constant speed gear is engaged. This affects all subsequent gears.
Design
Mercedes-Benz range-change transmissions comprise
• a 4-speed main transmission for 16-speed transmissions
• a 4-speed main transmission with additional crawler gear for 9-speed
transmissions
• a 3-speed main transmission for 12-speed transmissions
• a range group
• a splitter group for 12- and 16-speed transmissions
01/08 Range-change Transmission 46

Main transmission
The main transmission is the heart of the transmission and is located be-
tween the splitter group and the range change group. In the main transmis-
sion the force is transferred from the drive shaft or the countershaft to the
main shaft.
Range group
The range group is connected downstream of the other groups and is the-
refore also known as the rear-mounted group. The range group connects
the main shaft to the output shaft.
The ring gear carrier is blocked or held securely to permit a force to be
transferred from the main transmission to the output shaft. Two positions
can be engaged using the range group.
The range group is engaged using the sliding sleeve. The sliding sleeve is
splined on the ring gear carrier. The ring gear carrier projects through the
detent plate, which is permanently connected to the transmission housing.
When shifting forward, the sliding sleeve splines the ring gear carrier with
the detent plate (low range, slow position).
When shifting to the rear, the sliding sleeve splines the detent plate with
the transmission housing (high range, fast position).

Location of groups – 9-speed range-change transmission Location of groups – 16-speed range-change transmission
Red: Main transmission

Orange: Main transmission
Yellow: Crawler gear
Blue: Splitter range
Blue: Reverse gear
Green: Range group
Green: Range group

Transmission Overview Meaning of transmission designations
Vehicle model Transmission Transmission Transmission

designation model designa- code
tion
VITO
VARIO G56 - 6 712.611 GC4
ZF6S-850 710.010 GF9
ZF9S-75 710.600 GO5
ATEGO2 G56 - 6 712.611 GC4
G60-6 * 715.050 GC5
G85-6 * 715.060 GC6
G131-9 715.570 GT1
G85-6 * 715.060 GC6
G131-9 715.570 GT1 1 Transmission
G221-9 715.561 GD5 2 Maximum input torque (x 100)
AXOR2 G210-16 715.500 GC3
G211-16 715.510 GD3 3 Direct drive transmission
G240-16 715.520 GC2 4 Overdrive transmission
G211-12 K 715.350 GH2
5 Number of forward gears
G210-16 715.500 GC3
G211-16 715.510 GD3 6 Gear ratio in the slowest gear
G230-16 715.507 GH5 7 Gear ratio in the fastest gear
G231-16 715.513 GH6
G240-16 715.520 GC2
ACTROS2 G260-16 * 715.540 KGC1
G241-16 K 715.515 GH7
G280-16 K 715.525 GH4
G211-12 K 715.350 GH2
G281-12 K 715.370 GH3
G330-12 K 715-380 GH8
* G60-6 = Model designation 712.620 made in Brazil
G85-6 = Model designation 712.630 made in Brazil




Transmission shift
Shift type Mechanical shift Hydraulic shift Telligent Telligent Mercedes

gearshift system Automatic PowerShift
Gearshift System
Gearshift code GS1 GS3 GS2 GS7 GE1 GE2 GE3
Gearshift abbreviation MS MPS HS HPS2 GS GS2 AGS EAS2 EAS3
Vehicle Transmission Transmission Transmission
model designation model desig. code
ZF6S-850 710.010 GF9 X
ZF9S-75 710.600 GO5 X
G56 - 6 712.611 GC4 X X
ATEGO2
G60-6 * 715.050 GC5 X X
G85-6 * 715.060 GC6 X X
G131-9 715.570 GT1 X
G85-6 * 715.060 GC6 X X
G131-9 715.570 GT1 X
G221-9 715.561 GD5 X X
AXOR2 G210-16 715.500 GC3 X X X
G211-16 715.510 GD3 X X
G240-16 715.520 GC2 X X X
G211-12 K 715.350 GH2 X
* G60-6 = Model designation 712.620 made in Brazil

G85-6 = Model designation 712.630 made in Brazil
01/08 Gearshift 52
Shift type Mechanical shift Hydraulic shift Telligent Telligent Mercedes
gearshift system Automatic PowerShift
Gearshift System
Gearshift code GS1 GS3 GS2 GS7 GE1 GE2 GE3
Gearshift abbreviation MS MPS HS HPS2 GS GS2 AGS EAS2 EAS3
Vehicle Transmission Transmission Transmission
model designation model desig. code
G210-16 715.500 GC3 X X X
G211-16 715.510 GD3 X X X
G230-16 715.507 GH5 X X X
G231-16 715.513 GH6 X X X
G240-16 715.520 GC2 X X X
ACTROS2 G260-16 * 715.540 KGC1 X X X
G241-16 K 715.515 GH7 X
G280-16 K 715.525 GH4 X
G211-12 K 715.350 GH2 X
G281-12 K 715.370 GH3 X
G330-12 K 715-380 GH8 X
* Aftermarket installation (Molsheim)
Status: 01/2007 (not subject to update service)
Mechanical pneumatic shift (MPS)

The hydraulic gearshift is a manual gearshift with mechanical power trans-
mission and pneumatic shift assist.
The shift force is transferred from the gearshift lever to the transmission
via the gearshift linkage. The gears and the range group are shifted with
pneumatic assistance.
The gearshift linkage is adjustable.
01/08 Gearshift 53
Hydraulic-pneumatic power shift (HPS2) Gate cylinder
The gate cylinder is shifted by purely hydraulic means (low effort require-
The shift force is transferred from the shift control unit with two independ-
ment). It shifts the individual gates or the range group.
ent double-acting hydraulic circuits for gear and gate selection correspond-
ing to the movement of the gearshift lever (driver's intent) to the transmis- Gear cylinder
sion via one of the two hydraulic circuits. The slave cylinders for gear and The gear cylinder consists of a hydraulic cylinder, a pneumatic assistance
gate are seated at the transmission. The gears and the range group are cylinder and a solenoid valve unit (actuated by the HPS 2 control unit) for
engaged with pneumatic assistance. The gearshift linkage is omitted. shifting to an even or uneven gear.
The hydraulic-pneumatic power shift is installed in the ATEGO2, AXOR2 and
ACTROS2 vehicles in two different versions. These differ in terms of the
hydraulic transmission media
• Hydraulic fluid or
• brake fluid
In newer vehicles only hydraulic fluid as per Specifications for Operating
Fluids sheet 345.0 is still used. Shift systems with hydraulic fluid are rec-
ognizable from the green cap on the reservoir and from the green identifi-
cations for the pressure valves. The hydraulic-pneumatic power shift
(HPS2) is installed primarily in construction site vehicles.
Shift control unit
Two pressure sensors are located at the shift control unit. They record the
pressure in the hydraulic lines for "even gear" and "odd gear".
Gear and gate selection
Depending on the movement of the gearshift lever (driver's intent), the
hydraulic pressure is transferred from the shift control unit to the shift
cylinders for gear selection (6) via the hydraulic circuits.
Pneumatic power-assisted gear shifting
The two pressure sensors at the shift control unit record the hydraulic
pressure as a function of the shift force and pass this on to the HPS2 con-
trol unit. The HPS2 control unit evaluates the hydraulic pressure, calcu-
lates from this the necessary pneumatic shift force assistance and actu-
ates the solenoid valves accordingly by means of PWM signals.
01/08 Gearshift 54
Telligent® gearshift II Gear module
The gear module is an assembly and shifts the selected gears after the shift
The Telligent gearshift system II is an electropneumatic convenience gear-
shaft has been moved into the corresponding gate by the gate module. The
shift system and is available for all 12- and 16-speed synchromesh range-
change transmissions. There is no mechanical or hydraulic connection gear module includes the following components:
between the selector lever and the transmission. The shift command is • Gear shift cylinder
transmitted via the shift control unit to the collapsible mounting console at
the driver seat. The gears are actuated electronically, the intended gear is • Uneven gears air admission solenoid valve (MUB)
engaged pneumatically after actuating the clutch pedal. The transmission • Even gears air admission solenoid valve (MGB)
control is located directly at the transmission.
• Uneven gears air release solenoid valve (MUE)
In the "Driver selection" program the driver specifies the intended gear with
the gear selection. In the "Electronic selection" program the driver specifies • Even gears air release solenoid valve (MGE)
the shift command, as a result of which the control unit automatically
selects the optimal connection gear. For this, parameters such as the
accelerator pedal position, speed, torque request, acceleration in the cur-
rent gear and - on vehicles with air suspension - vehicle weight are consid-
ered.
The following functions can be controlled by operating from the multifunc-

tion steering wheel:
• Backup mode with the 2nd and 5th gear, reverse gear, neutral, with gear
indicator
• Tow-start, roll-start in the 3rd or 4th gear
• Towing with automatically engaged range-change transmission range
group
01/08 Gearshift 55
Gate module Range module
The gate module is an assembly and contains the following components:
The range module is an assembly and contains the following components:
• Housing with shift piston • Range shift cylinder
• Splitter 1 solenoid valve (MS1) • Range sensor (SRA)
• Splitter 2 solenoid valve (MS2) • Range 1 solenoid valve (MR1)
• Gate 1 solenoid valve (MG1) • Range 2 solenoid valve (MR2)
• Gate 2 solenoid valve (MG2) When shifting the range group, the solenoid valves are energized in accor-
• Gear control (GS II) control unit dance with the shift logic until the corresponding position for the range
group is engaged.
When shifting the gate and the splitter group, the solenoid valves are ener-
gized in accordance with the shift logic until the corresponding positions
for gate and range group are engaged.
01/08 Gearshift 56
Telligent® automatic gearshift system EAS II Clutch actuator
The Telligent automatic gearshift system II (EAS II) is a special version of The following components are integrated in the clutch actuator:
the Telligent gearshift system II with an automated clutch. The driver is now • Solenoid valves:
provided with just the accelerator pedal and the brake pedal. The overall − Clutch air admission 1
system is comprised of the following subsystems:
− Clutch air admission 2
• Telligent engine system, comprising drive control and engine control − Clutch air release 1
including unit pumps − Clutch air release 2
• Clutch regulation, comprising clutch control • Clutch travel sensor
• Actuator cylinder
• Automatic gear selection
The clutch actuator receives the electrical signals for the clutch operation
The automatic gear selection takes place depending on the driving state,
and actuates the mechanical clutch components with pneumatic assis-
accelerator pedal position and the engine's operating condition. The clutch
tance.
is operated by an electropneumatic clutch actuator. The driver can switch
between automatic and manual gear selection using a switch or button on Every clutch position can be approached and retained via the four solenoid
the gear control shift control unit. During manual gear selection the Telli- valves. Applying to this:
gent automated gearshift II continues to control the clutch operation as Cylinder extended → Clutch open
well as the gear change. Cylinder retracted → Clutch closed
The menu for the Telligent automated gearshift II is displayed on the driver The clutch travel sensor detects the current position of the clutch actuator.
information display (FIS). Selections are made within the menu using the
buttons on the multifunction steering wheel. In the menu it is also possible
to start the backup drive mode if regular driving mode can no longer be
guaranteed.
The clutch control (KS) control unit is integrated as the clutch regulation
(KR) software module in the FR control unit. The clutch operation (KB) is
integrated in the gear control II (GS).
01/08 Gearshift 57
Note
On vehicles with Telligent automated gearshift II, a one-time change of the
fine-mesh filter in the clutch actuator must be done during the first general
maintenance.
Emergency shifting with the emergency switch

The emergency switch is integrated into the shift control unit and can be However, if the control unit detects a fault that only permits driving to
operated after opening the cover. continue in emergency shift mode, all Telligent° shift operations are blo-
In its basic position the emergency switch is nonfunctional cked. Emergency shift mode remains blocked in driving operation. Emer-
gency shift mode can only be actuated via the emergency switch once the
• provided the vehicle is being driven vehicle is stationary.
• if the key in the steering lock is in the driving position and there is no Emergency shift mode is enabled for most severe faults (group 2) detected
fault indicated in the Telligent gearshift system. by the system.
Emergency shift mode is enabled when the vehicle is stationary. However, if the control unit detects faults for which actuation of emergency
shift mode will not result in the desired success or will even cause unde-
If a fault is detected that still permits Telligent shift operation and does not
sired shift states, it prevents the emergency shift mode enable.
influence emergency shift mode, emergency shift mode remains blocked in
driving operation. Emergency shift mode is only enabled if it is actuated
when the vehicle is stationary.
01/08 Gearshift 58
Notes: R Reverse gear
• Only operate emergency shift mode when the vehicle is stationary. G: Basic position
• While driving, a gear change from 2nd to 5th gear is possible. 2: 2nd gear
The individual shift positions can only be shifted in sequence, the gears NL: Neutral (range group
can only be shifted from the transmission neutral position (N). slow)
NH: Neutral (range group
• If emergency shift mode is not possible with the emergency switch,
fast)
emergency shifting can be carried out at the transmission.
5: 5th gear
Emergency shifting the transmission

When emergency shifting the transmission, gears 1 – 4 and the reverse
gear can be engaged by manually shifting and turning the shift shaft with
the aid of adjustment screws and a special tool. The following must be
observed in this case:
• Emergency shifting of the transmission may only be performed when
the vehicle is stationary, the parking brake is applied and the engine is
turned off. The key in the steering lock must be turned back to the
stop.
• The cab must be fully tilted forward.
• Always turn the shift shaft from the center position (transmission neu-
tral position) to the end stop. Use the special tool for this. If the shift
shaft does not latch into the end stop, turn the shift shaft to the center
position. Fully depress the clutch pedal before starting the engine.
• It is only possible to drive with the gear engaged. Gears cannot be
changed while driving. 1. Adjustment screw for gears 3 and 4
• Emergency shifting the transmission may only be used on synchromesh 2. Adjustment screw for reverse gear
transmissions
3. Special tool for turning the shift shaft
The adjustment screws and the special tool for emergency shifting (3rd/4th
gear and reverse gear) can be found in the vehicle tool kit.
01/08 Gearshift 59
Mercedes PowerShift
Mercedes PowerShift is based on the Telligent automated gearshift II. As
the synchronization has been omitted on PowerShift transmissions, the
Mercedes PowerShift adapts the rotational speeds of the main shaft and
the gearwheel through the electronic engine or transmission control.
When upshifting, the countershaft brake brakes the countershaft, when
downshifting this is accelerated by increasing the engine speed.
The gear is not engaged until synchronism is achieved between the coun-
tershaft and the main shaft. (difference in speed < ± 50 rpm).
Additional functions of Mercedes PowerShift:

• Power mode: • Expansion of cruise control function I (speed range):
− Permits brief utilization of the full engine power − Permits individually adjustable speed range between 2 km/h and
15 km/h between drive and brake use
• EcoRoll mode:
• Expansion of cruise control function II (separate speed memory):
− Supports a fuel-saving driving style in deceleration mode
− Stores the settings for cruise control or adaptive cruise control and
• Maneuver mode:
variable speed limiter separately, the settings being retained when
− Provides a finely modulated power demand up to 1000 rpm via the switching back and forth
accelerator pedal in maneuvering applications.
• Fast reverse gears:
• Rocking mode
− Permit faster speeds when backing up.
− Simplifies starting off on difficult ground
• Direct shifting from "1" to "R":
− Skips the intermediate step via the "Neutral" position
01/08 Gearshift 60

01/08 Gearshift 61
6-gear synchromesh transmission
G56 - 6
Transmission G 56-6 is an overdrive transmission with 6 synchronized
forward gears and one reverse gear.
In the VARIO this transmission is installed in all variants.
In the ATEGO the G56-6 is installed in vehicles up to 10.5 t in conjunction
with engine OM 904LA with a maximum of 130 kW.
G60-6
Transmission G 60-6 is a direct drive transmission with 6 synchronized
forward gears, and one reverse gear and is designed for a total traction
weight of up to a maximum of 24 t.
In the ATEGO the G60-6 is installed in vehicles from 9.5 t to 13.5 t in con-
junction with the 130 kW version of engine OM 904 LA.
For the VARIO the transmission is available as special equipment for heavy-
duty use (e.g. construction sites) as well as for frequent trailer operation -
in conjunction with the 130 kW version of engine OM 904 LA.
The G60-6 is available with power take-offs for mechanical and hydraulic
power take-up.
01/08 6-speed Synchromesh Transmission 62

G85-6
Transmission G 85-6 is an overdrive transmission with 6 synchronized
forward gears, and one reverse gear and is designed for a total traction
weight of up to a maximum of 32 t.
In the ATEGO the G85/6 is installed in vehicles of 7.49 t and above in con-
junction with OM 924 LA with 160 kW and the OM 906 LA engine versions
of 175 - 210 kW.
In the AXOR the G85-6 is the lightest transmission and is available with the
175 kW version of OM 906 LA.
The G85-6 is available with power take-offs for mechanical and hydraulic
power take-up.
ZF transmission 6S-850/6
ZF transmission 6S-850/6 is a compact direct drive transmission with
6 synchronized forward gears and one reverse gear.
The transmission is installed in ATEGO fire-fighting vehicles with a permis-
sible gross vehicle weight of 7.49 t.



G131-9
forward gears, one constant-mesh crawler gear and one reverse gear. It
comprises a 4-speed main transmission with pneumatic range group and
is designed for a total traction weight of up to a maximum of 44 t.
Short shafts and a small number of mechanical and electronic compo-
nents make this transmission lightweight and sturdy.
The G131-9 was configured for a maximum input torque of 1300 Nm and
is designed for engine series 906/926 with an engine power of 188 -
240 kW (256 - 326 hp) and is available exclusively for the hydraulic-
pneumatic power shift (HPS2).
Transmission G 131-9 is available for the ATEGO and AXOR in combination
with engines OM 906 LA and OM 926 LA.
The G131-9 is available with an integrated hydraulic retarder and power
take-offs for mechanical and hydraulic power take-up.
For special applications it is possible to connect an external transmission
cooler.

G221-9
forward gears, one crawler gear and one reverse gear. It comprises a
4-speed main transmission with pneumatic range group and is designed
for a total traction weight of up to a maximum of 45 t.
8 forward gears, which are stepped close together, permit an optimal
traction connection following every shift operation. The additional crawler
gear also provides good slope climbing ability.
The G221-9 has a maximum input torque of 2200 Nm and is adapted to
the high torques of OM 457 LA. The G221-9 is only available for the AXOR.
The G221-9 is available with an integrated hydraulic retarder or an eddy
current brake and with power take-offs for mechanical and hydraulic po-
wer take-up.
For special applications it is possible to connect an external transmission
cooler.
ZF transmission 9S-75
The 9-speed Ecomid transmission 9S-75 is installed as standard equip-
ment in the ATEGO in steel- and air-sprung municipal vehicles. It is de-
signed for a maximum input torque of 770 Nm.
The transmission is only available with a mechanical double H shift.



G210-16 & G211-16

forward gears and one reverse gear. It comprises a 4-speed main trans-
mission with pneumatic or electropneumatic range group and a splitter
group connected upstream. The two transmissions are designed for a total
traction weight of up to 45 t.
In terms of its design the G211-16 corresponds to the G210-16, but is
designed as a direct drive transmission.
Both transmissions have a maximum input torque of 2100 Nm and are
adapted to the high torques of engines OM 457 LA and OM 501 LA. The
two transmissions are available for the AXOR in combination with OM 457
LA for all power variants, in the ACTROS only with OM 501 LA with an en-
gine power of 235 kW – 320 kW.
G230-16 & G231-16
Transmissions G230-16 and G231-16 are based on transmissions G210-
16 and G211-16 and have been reinforced to absorb higher input torques
of up to 2300 Nm.
The two transmissions are available in the ACTROS with OM 501 LA with an
engine power of 335 kW and 350 kW.
The G230-16 is designed for a total traction weight of up to a maximum of
45 t, the G231-16 for up to a maximum of 40 t.

G240-16 and G260-16
forward gears and one reverse gear. It comprises a 4-speed main trans-
mission with pneumatic or electropneumatic range group and a splitter
group connected upstream.
In terms of its design the G260-16 corresponds to the G240-16, but it has
been reinforced for a maximum input torque of 2600 Nm.
Both transmissions are designed for a total traction weight of up to a ma-
ximum of 55 t and are only installed in combination with the HL7 axle.
The G240 is available for the AXOR with the OM 457 LA for all power vari-
ants, in the ACTROS with engines OM 501 LA and OM 502 LA with an en-
gine power of 300 kW up to 405 kW, the G260-16 is only available in the
ACTROS with OM 502 LA.
Redirected shift mechanism for G240-16 with MPS and HPS shift
mechanism
The design of the main shaft means that the driver would have to engage
the fourth gear forwards and the third gear to the rear. However, the redi-
rected shift mechanism permits the usual shift pattern to be retained, the
third gear is moved forwards as in all other transmissions and the fourth
gear is moved to the rear.
Additional equipment
Transmissions G210-16 to G260-16 can be combined with power take-offs
with a power input of up to 2000 Nm as well as a hydrodynamic retarder
or an eddy current brake.
Transmission oil cooling
Transmission oil cooling is mandatory for vehicles with a permissible gross
vehicle weight of more than 44 t, if a Telma retarder is installed and for
applications in hot countries. Vehicles with OM 502 LA engine with
425 kW and above are fitted as standard with transmission oil cooling.

Mercedes PowerShift transmission - 16-speed
G241-16 K
The Mercedes PowerShift G 241-16 is a fully automated direct drive trans-
mission with 16 forward and 4 reverse gears. It comprises a 4-speed main
transmission with splitter group and range group and is designed for a total
traction weight of up to a maximum of 45 t.
The Mercedes PowerShift G241-16K has been configured for a maximum
input torque of 2400 Nm and is available for the ACTROS2 with engines
OM 501 LA and OM 502 LA and an engine power of 335 kW to 375 kW.
In future the G241-16K will be installed as standard instead of the syn-
chromesh transmissions G 211-16, 231-16 and G240-16, the synchromesh
transmissions are however still available as special equipment.
G280-16K Additional equipment

The Mercedes PowerShift G 280-16K is an overdrive transmission and in Transmissions G241-16K and G280-16K can be combined with power
terms of its basic design corresponds to the G241-16K but is reinforced for take-offs with a power input of up to 2000 Nm as well as a hydrodynamic
a maximum input torque of 2800 Nm. retarder or an eddy current brake.
The Mercedes PowerShift G 280-16K is available for the ACTROS2 with
engines OM 501 LA and OM 502 LA and an engine power of 235 kW to
440 kW, however at an engine power of 335 kW and above only in combi-
nation with the rear axle HL7.
In future the G280-16K will be installed as standard instead of the syn-
chromesh transmissions G 210-16, 240-16 and G260-16, the synchromesh
transmissions are however still available as special equipment.
01/08 Mercedes PowerShift Transmission - 16-speed 70

Mercedes PowerShift transmission - 12-speed
G211-12K
The Mercedes PowerShift G 211-12 is a fully automated direct drive trans-
mission with 12 forward and 4 reverse gears. It comprises a 3-speed main
transmission with splitter group and range group.
The Mercedes PowerShift G241-16K has been configured for a maximum
input torque of 2100 Nm and is available for the ACTROS2 with engines
OM 501 LA and with an engine power of 335 kW to 375 kW, and in the
Axor 2 with the OM 457 LA in all power stages.
In future the Mercedes PowerShift transmission G211-12K will be installed
as standard instead of the synchromesh transmission G 210-16 and
G211-16, the synchromesh transmissions are however still available as
special equipment.
G281-12K and G330-12K Additional equipment

In terms of their design and function the Mercedes PowerShift direct drive Transmission G211-12K can be combined with power take-offs with a
transmission G 281-12K and the overdrive transmission G330-12K corre- power input of up to 2000 Nm as well as with the hydrodynamic retarder
spond to the G211-12K, but are designed for maximum input torques of R115HV, while transmissions G281-12K and G330-12K are also combin-
2800 Nm and 3300 Nm. able with an eddy current brake.
The Mercedes PowerShift G 281-12K is available in the Actros for engines
OM 501 LA and OM 502 LA with an engine power of 335 kW to 440 kW,
the Mercedes PowerShift G 330-12K is available for all engine variants of
the Actros2.
In future the Mercedes PowerShift transmission G281-12K will be installed
as standard instead of the synchromesh transmission G 231-16 and
G240-16, while the G330-12K replaces the transmissions G210-16,
G231-16 and G260-16. The synchromesh transmissions are however still
available as special equipment.
01/08 Mercedes PowerShift Transmission - 12-speed 71

Power take-offs (NA)
Rear engine-mounted PTO

Engine-driven PTO (live power take-off)
Transmission-driven PTO 1 and 2
Front engine-mounted PTO
Transmission-driven PTO 1
N23.00-2001-09
01/08 Power Take-offs (NA) 72

Depending on the design and application of the vehicle, the customer can Engine-driven PTO
choose the most suitable from a variety of power take-offs. The technical data
The engine-driven power take-off is attached to the drive side of the engine
for these are stored in the body/equipment mounting directives
together with the bell housing. It is designed for a high output and a high
(http://abh-infoportal.mercedes-benz.com/portal/ar.0.html). The power
torque. The engine-driven power take-off is driven by the main transmission's
take-offs illustrated relate to the ACTROS2 and AXOR2 model series.
drive shaft, which is guided through a hollow shaft.
Front camshaft-driven PTO
The force is transferred independently of the drive clutch. The engine-driven
The front camshaft-driven PTO is driven via the V-belt and is not switchable. power take-off can be switched on and off under load via a hydraulically actu-
The transmission ratio is reached by means of the diameters of the additional ated multidisk clutch and can be operated when the vehicle is stationary or
belt pulleys. The transmission ratio is determined by the diameters of the belt being driven.
pulleys. Maintenance
Primary uses: An oil filter is installed in the oil circuit to protect the hydraulic valves of the
• Drive for refrigeration units engine-driven power take-off from any contamination. This must be changed
at every transmission oil change.
Rear camshaft-driven PTO
The rear camshaft-driven PTO is driven via the wheels of the camshaft and is
not switchable. The rear camshaft-driven PTO also turns as soon as the engine
is running. The maximum transferable drive torque is 600 Nm.
Primary uses:
• Drive for concrete mixers
• Drive for hydraulic pumps, which also need to be operated while driving
(in combination with an intermediate flange)

Transmission-driven power take-off (NA1) Dual transmission-driven power take-off (NA1 & NA2)
The transmission-driven power take-off is designed for low, moderate and high The dual transmission-driven power take-off with flange and Meiller pump
speeds, depending on the variant, and is switchable. It is attached to the drive under frame (MPA) comprises two separately switchable power take-
transmission countershaft and is driven by this via a 2-shaft spur gear drive. It offs and is designed for low, moderate and high speeds, depending on the
is not possible to install it in combination with a Telma retarder or with low variant. Both power take-offs are attached to the transmission countershaft
frame heights. and are driven by this via a 2-shaft spur gear drive. The outer power take-off
is for flange-mounting a propeller shaft, the inner for directly flange-mounting
Primary uses:
a hydraulic pump (MPA).
• Low and moderate rotational speeds:
Primary uses:
− For operating vacuum pumps and compressors by means of an addi-
• Drive for vacuum pumps or compressors, e.g. for semitrailer tractors with
tional propeller shaft
tilting dry-bulk semitrailers etc.
• High rotational speeds:
• Permits the cost-effective drive of a body assembly with a high torque by
− Drive for vacuum pumps or compressors, e.g. for semitrailer tractors means of an additional propeller shaft and a hydraulic pump (MPA)
with tilting dry-bulk semitrailers



Transfer Case
2-speed transfer case

The 2-speed transfer case distributes the force of the drive shaft among
the front and rear axle(s). The axles are driven continuously; switching on
and off separately is not required. The three-shaft transfer case has an on-
road ratio, an off-road ratio and an engageable interaxle differential lock.
The planetary gear set distributes the input torque among the front and
rear axle(s). Rotational speed compensation between the front and rear
axle(s) also takes place via this planetary gear set. The sun gear drives the
front axle(s), the ring gear drives the rear axle(s).
When driving on a smooth road surface or soft ground, the compensation
between the front and rear axle is blocked and the traction of the front and
rear axle is improved. The distribution of the input torque is suspended if
the interaxle differential lock is engaged.
The off-road ratio ensures high tractive forces e.g. on steep ramps and in
difficult terrain.
Note:
The off-road or on-road gear may only be engaged when the vehicle is
stationary.
1-speed transfer case
The 1-speed transfer case is suitable for all-wheel drive vehicles with tor-
que converter clutch and Telligent automated gearshift II. The off-road ratio
is dropped. 1 Transfer case
2 Input torque (x 10 Nm)
3 Number of shafts
01/08 Transfer Case 76

Transmission Torque distribution Gear ratio Gear ratio Usage Max. engine power/
designation between front axle and rear On-road Off-road engine torque
axle
VG550 – 3W 1:2.62 1,037 1,67 Vario/Atego 110 kW/580 Nm
VG900 – 3W 1:3.35 1.0 1.691 Atego/Axor 180 kW/900 Nm
VG1400 – 3W 1:3.35 1.0 1.691 Axor 240 kW/1300 Nm
VG1700 – 3W 1:3.35 1.0 1.691 Actros 235 kW/1650 Nm
VG1700 – 3W 1:3.21 1.0 1.403 Actros 235 kW/1650 Nm
VG1700 – 3W 1:3.21 1.0 ----- Actros 235 kW/1650 Nm
VG2400 – 3W 1:3.21 1.030 1.448 Axor/Actros 375 kW/2400 Nm
VG2400 – 3W 1:3.21 1.030 ------ Axor/Actros 375 kW/2400 Nm
Transfer case oil cooling system

The transfer cases VG 1700 and VG 2400 can be equipped with an oil
cooler on vehicles intended for heavy-duty service or used in high outside
temperatures.
When the oil in the transfer case is changed, this oil cannot be drained;
approx. 2 liters of oil remains in the oil cooler.
01/08 Transfer Case 77

Front Axles
VL0/7
The non-driven front axle VL0/7 is a suspension strut front axle with trans-
verse leaf parabolic spring, stabilizer bar and independent wheel suspen-
sion. The axle is installed in the SPRINTER.
On vehicles with a permissible gross vehicle weight of 4.6 t and above a
glass fiber reinforced plastic leaf spring is installed as standard, for 3.5 t
vehicles the glass fiber reinforced plastic spring is available in combination
with the reinforced front axle.
VL1
The non-driven front axle VL1 is a rigid axle with stabilizer bar, parabolic
springs and shock absorbers. The axle is installed in the VARIO and is de-
signed for an axle load of 2.5 t.
L2
The non-driven front axle VL2 is a low-maintenance rigid axle with forged
axle housing and is installed in the ATEGO. It is designed for axle loads of
3.5 t and 4.1 t, with low-frame vehicles for 4.4 t. It is particularly suitable
for distribution transport because of the high degree of maneuverability
and the large outside wheel turn angle.
The axle is available:
• in an offset version
• with internally vented disk brakes
• with drum brakes
• with steel or air suspension
The axle is equipped as standard with ABS sensors as well as a sensor
system for the brake wear indicator.
01/08 Front Axles 78

VL3
In terms of its design and function the non-driven front axle VL3 corre- The straight front axle is the standard axle for all vehicles requiring in-
sponds to the front axle VL2. It is installed in the ATEGO and is designed for creased ground clearance. The front axle is straight in the area of the axle
axle loads of 5.3 t, 5.7 t and 6.1 t. beam ends. Compared with the offset axle version, the axle beam ends and
VL3 with air suspension the axle housing are almost flat, with the result that the ground clearance
under the axle housing is increased by up to 85 mm - depending on vehicle
The air-sprung front axle is – depending on the weight variant - designed for
version and tires. For vehicle components that are mounted on the vehicle
axle loads of 4.4 t to 5.1 t. It is available for vehicles of 12 t and above in
frame in this area (e.g. cab, etc.), the overall height increases accordingly.
combination with the air-sprung rear axle.
The VL4 front axle is only installed in combination with steel suspension,
the air-sprung variants only in combination with the air-sprung rear axle.
VL4 and VL5

In terms of design and function the non-driven stub front axles VL4 and
VL5 correspond to the front axle VL3. They are installed in the AXOR and
ACTROS and are designed for the following permissible axle loads:
• VL4: 7.5 t and 8 t
• VL5: 9 t
Depending on the usage, straight or offset axle designs may be installed.
The offset front axle is the standard axle for almost all road vehicles with
lowered frame or vehicle level over the front axle. The front axle is de-
signed upwardly offset in the area of the axle beam ends. The axle housing
is therefore much lower, with the result that the ground clearance, the
frame height as well as the overall height of the bodies over the front axle
are reduced by the size of the offset.
The air-sprung front axle is installed only in combination with the air-sprung
rear axle.

Driven front axle AL3 Driven front axle AL4 & AL5
The front axle AL3 is a modular planetary axle with steel suspension and is In terms of design and function the driven front axles VL4 and VL5 corre-
installed in the ATEGO with all-wheel drive. It is fitted with drum brakes, has spond to the front axle VL3. They are installed in the AXOR and ACTROS and
a load capacity of 4.7 t or 6.1 t, and is used with 20" or 22.5" rims. The are designed for the following permissible axle loads:
axle is low-maintenance and easy to service and is equipped as standard • VL4: 7.5 t and 8 t
with differential lock, ABS sensors as well as a sensor system for the brake
wear indicator. • VL5: 9 t
On four-axle vehicles, through-drive axles with a 9 t permissible axle load

and standard differential lock are installed as the second front axle.
Front axle differential lock

The differential lock at the front axle suspends the compensation effect of
the differential by means of a pneumatically operated locking mechanism.
The driven front wheels are rigidly connected together via a dog clutch and
are thus blocked in the transverse direction.
Note:
• The differential lock at the rear axle must be engaged before switching
on the differential lock at the front axle.
• The differential lock(s) may only be switched on when the vehicle is
stationary or moving at walking pace.
• The vehicle's steerability is impaired when the differential locks are
switched on.
The differential locks may only be switched on when the ground is slippery.
Driving with the differential locks can cause damage.
Oil change
At an oil change at the front axles AL3, AL4 and AL5, in addition to the
center axle housing the oil must also be changed on the outside at the
planetary gear systems.

Rear Axles
HL0
The rear axle HL0 is a rigid axle with parabolic springs, stabilizer bar and
shock absorbers. It is installed in the SPRINTER and is designed for an axle
load of 1.8 t to 3.5 t.
HL2
The series HL2 rear axle variants are sheet steel conversion axles which
are designed for steel- and air-sprung vehicles. The HL2 hypoid rear axles
are low-maintenance and easy to service and are equipped with disk bra-
kes, which are actuated pneumatically and are internally ventilated, de-
pending on the design. It is installed in the VARIO and designed for an axle
load of 4.3 t and 5.6 t. Installed in the ATEGO are the variants with a 6.2 t
and 7 t axle load, for low-frame vehicles with an 8.5 t axle load.
HL4
In terms of design and function, the rear axle HL4 corresponds to the rear
axle HL2. It is installed in the ATEGO and is designed for axle loads of 7 t to
11 t. The 11 t variant is also installed in the AXOR, primarily for 6x4 and
8x4 vehicles.
01/08 Rear Axles 81

HL6
The hypoid rear axle HL6 has a single-speed ratio and is available in a steel
or air suspension version. It is sturdy, heavy-duty and has a load capacity of
up to 13 t.
The HL6 rear axle is installed in AXOR and ACTROS road vehicles with the 6-
cylinder engines with engine powers up to 350 kW and a permissible gross
vehicle weight of 44 t. The hypoid gearing ensures smooth running charac-
teristics at low friction losses. The drive shafts are mounted using compact
bearings in a maintenance-free way. The axle ratios are dependent on the
drivetrain used and the tires. The permissible rear axle load is calculated
from the selected weight variant as a function of tires and suspension.
Included in the equipment for the 13 t hypoid rear axle are:
• Differential lock
• Internally ventilated disk brakes
• Oil temperature sensor for the maintenance system
HL8
In terms of design, equipment and function the hypoid rear axle HL8 corre-
sponds to the HL6 and covers an output range from 370 kW to 440 kW at a
permissible gross vehicle weight of 44 t. It is installed in the ACTROS in
combination with OM 502 LA engines.
Compared with the HL6 axle, it has a larger ring gear diameter due to the
higher power transmission and therefore has less ground clearance under
the differential assembly.
The HL8 axle is not suitable for low-frame vehicles because of the reduced
ground clearance.
01/08 Rear Axles 82

HL7
The planetary hub reduction rear axle H7 has a cast axle beam and is suit-
able for heavy-duty construction site and offroad applications as well as
long-distance haulage with a 440 kW engine. The two-stage step-down
ratio permits a high ground clearance. The permissible axle load is 13 t. An
axle load of 16 t is possible in combination with drum brakes.
The center drive part (ring gear and pinion) is exchangeable as a unit.
Planetary gear systems are fitted on the left and right of the hubs. The
driving power is transferred to the planetary gear system via the ring gear
and pinion as well as via the rear axle shafts. The sun gear of the planetary
gear system is seated on the rear axle shaft and drives the planetary gears,
which are mounted on the planet carrier.
Because of the two-stage gear ratio (at the differential assembly and the
planetary gear system) the differential assembly is relatively small, as the
main ratio with a large torque takes place in the planetary gear systems
and the full torque is not effective until at the wheel hubs. As a result, the
load on all the force transfer elements is considerably less. The small dif-
ferential assembly permits good ground clearance. Different gear ratios are
possible for the differential assembly.
01/08 Rear Axles 83

HD7
The HD7 axle is a through-drive axle and is installed as the first rear axle on
vehicles with two driven rear axles. The transmission transfers the drive
torque via a propeller shaft to a differential, which is located in the through-
drive. There it is split via a spur gear hub drive to the drive pinion of the
first rear axle and via an intermediate shaft to the second rear axle. The
differential in the through-drive permits a speed compensation between the
first and the second rear axles. A block is installed as standard in the
through-drive. When the block is activated, the differential is blocked by
means of an air-operated shift dog and the first and second rear axles are
rigidly connected together.
Oil change
At an oil change at the HL 7 and HD7 axles, in addition to at the center axle
housing the oil must also be changed on the outside at planetary gear
systems.
01/08 Rear Axles 84

HL6 axle concept and super-wide tires
A significant gain in payload is achieved through innovative technical

equipment such as the new axle concept and the new single-tire rear axle
with super-wide tires.
The rear axle HL 6 with just two air bellows for the semitrailer tractors up
to 350 kW (478 hp) is around 90 kg lighter than the cast axles previously
used.
A further gain in payload of approx. 200 kg is possible with the optionally
available single tires at the drive axle with super-wide tires. This reduces
the rolling resistance and thus the fuel consumption.
With single tires the previously used twin tires are replaced by very wide
and extremely load bearing super-wide tires sized 495/45 R 22.5. Inte-
grated in the super-wide tires are a tire emergency running concept and a
tire pressure monitoring system.
01/08 HL6 Axle Concept and Super-wide Tires 85

Brakes
The brake systems in the VARIO, ATEGO, AXOR, ACTROS and ECONIC are
usually equipped as standard with an air brake system and disk brakes with
2-piston brake calipers, internally ventilated brake disks and automatic
brake adjusters in combination with wear indicator.
Apart from the VARIO and ECONIC, all vehicles are equipped as standard
with the Telligent® brake system.
Vehicles with drum brakes have automatic linkage adjusters at the particu-
lar axles.
Self-adjusting brakes
The self-adjusting brakes permit a constant clearance to be maintained
between the brake pads and the brake disk on disk brakes. The clearance
is adjusted during the release stroke on actuating the brake starting at a
specific idle travel value. Adjustment by hand is not required.
Notes on maintenance
• The proper operation of the self-adjusting brakes must be checked
prior to the safety inspection (SP), main inspection (HU) and when
changing the brake pads
• Turn back the brake adjusters before changing the brake pads
• Check the brake caliper guides for ease of movement when changing
the disk brake pads
Tighten the brake adjusters by hand after replacing the brake pads and
turn back approx. 2 – 3 detent segments
01/08 Brakes 86
Service limits
With brake disks the area of wear is recognizable from the two chamfers on
the brake disk. If the two chamfers are no longer visible, the brake disk has
just about reached its wear limit. In this case, the brake disk thickness
must be checked with respect to the permissible wear dimension. If the
brake disk has reached or is below the wear dimension, the prescribed
maintenance or repair operations must be carried out.
For vehicles with drum brakes the inside diameter of the brake drum must
be measured and compared with the specified maximum diameter.
Drum brakes
The drum brake system is a closed system, into which foreign objects
cannot penetrate from the outside. The use of drum brakes is therefore
recommended particularly for construction site vehicles. All-wheel drive
vehicles are equipped ex works with drum brakes and also have the ABS
that can be deactivated. A mixed configuration is used for vehicles that are
used both on-road and off-road: For example, steel-sprung 4x2 and 6x4
dumpers are equipped as standard with disk brakes at the front axle and A Total thickness of new brake disk
drum brakes at the rear axle. Full protection is available for the brake disks B Wear dimension
for 6x4 and 8x4/4 Axor and Actros vehicles that are equipped with disk
brakes at the rear axles. C Degree of brake disk wear
per side
01/08 Brakes 87
Spring-loaded parking brake
The spring-loaded parking brake is a linkage-free spring brake that usually
acts on the rear wheels. As special equipment the spring-loaded parking
brake is also available for the front axle.
The brake force is generated by a strong spring, which is installed in the
spring-loaded brake cylinder. The advantage of this is that the brake is
operative even if the reservoir pressure fails. When the brake is released,
the spring is pre-compressed with compressed air, which acts on a piston,
and this relieves the piston rod.
For braking, the spring-loaded actuator is vented with the aid of the parking
brake valve. The spring force therefore acts on the wheel brake via the
piston rod.
When the lever is engaged (full brake position), the trailer or semitrailer is
also braked.
In the test position it can be determined whether the parked and laden
tractor/trailer combination can be held on inclines or slopes just by the
spring-loaded actuator force of the tractor vehicle.
Releasing mechanically
To release the brake correctly, the reservoir pressure must be greater than
6.8 bar (release indicator lamp goes out).
If there is no external air source provided, the spring-loaded actuator can
be released via the mechanical release device of the spring-loaded actua-
tor. To this end, the release screw on the combination cylinder is un-
screwed as far as possible.
Note:
Before the initial startup of the vehicle, reset the spring-loaded actuator
diaphragm cylinder back into the functional state.
01/08 Brakes 88
Air drier Tire inflation connection
In the air drier the water vapor contained in the compressed air is drawn The tire inflation connection is located on the front of the air drier and is
from the compressed air supplied by the air drier in the granulate cartridge. used to:
The dried compressed air passes from there via a check valve to the down- • Inflate tire
stream compressed air reservoirs. The accumulated condensation passes • Fill the compressed air system externally
into the atmosphere via the vent.
Note
Condensation • When filling the compressed air system via the tire inflation connection,
If it can no longer be guaranteed that air will pass through the cartridge the compressed air is not cleaned and not dried
because of the soiling of the filter, for example, undried air passes directly • The pressure protection provided by the pressure regulator is also
to the 4-circuit protection valve and the condensation accumulates in the bypassed
compressed air reservoir. At the lowest point of the compressed air reser-
voir there is a condensation sensor that records the condensation level and
indicates this via an indicator in the maintenance system. The indicator can
be hidden in the maintenance system, but it appears again in the display
field after the engine is started and reminds the driver that a service is
necessary.
Since a small amount of oil always passes from the air compressor into the
granulate cartridge even when functioning without faults, its water absorp-
tion capacity decreases. The granulate cartridge must therefore be re-
placed as part of the prescribed maintenance operations.
01/08 Brakes 89
Permanent brakes
Depending on the model, engine version and total vehicle weight, ATEGO, For vehicles with retarder, 20 % of the possible permanent braking power is
AXOR, ACTROS and ECONIC vehicles are fitted with an integrated permanent available with each of the 5 stages. The stages combine the braking powers
brake system that comprises a constant throttle and an exhaust valve of the engine brake system (constant throttle and engine brake) and the
brake. The system relieves the service brake and preserves the brake pads retarder in increasing strength (20 %, 40 %, 60 %, 80 %, 100 %). For vehicles
particularly in the case of relatively long periods of downhill driving. This without retarder, stage 1 activates the constant throttle. Stage 2 addition-
reduces the maintenance costs for the service brake. The brake force of ally switches on the exhaust valve brake. For laden vehicles equipped with
the permanent brake system can be modulated well, enabling high average Telligent® brake system the integrated permanent brake system always has
speeds also to be achieved when driving downhill with a preventive driving priority over the service brake even when operating the foot brake. This
style. This supports an economic driving style - without forfeiting safety. considerably reduces the brake wear.
The permanent brake can be switched on and modulated via the operating
lever at the steering column. Depending on the vehicle equipment there are
two power stages (without retarder) or five power stages (with retarder).
Constant throttle
The constant throttle is an additional brake. It is installed as standard
depending on the model, engine version and total vehicle weight. The
associated valve is integrated into the cylinder head. This brake system
boosts the braking effect of the engine - and in doing so relieves the ser-
vice brake.
01/08 Permanent Brakes 90

Exhaust valve brake
The exhaust valve brake is the second standard engine brake in addition to
the constant throttle. The braking power is achieved by closing the exhaust
flap. This creates a back pressure, which brakes the movement of the
piston and therefore the engine. The fuel supply is interrupted at the same
time.
Turbobrake
The turbobrake is an innovative brake system that increases the maximum
braking effect of the engine by around 50 percent in conjunction with the
constant throttle. As a result, the braking power is considerably greater
than the engine's operating energy input. The turbobrake is based on the
conventional turbocharger. The main feature is an activatable deflector at
the exhaust turbine wheel. If an increased engine braking effect is required,
the ring-shaped deflector is activated and this increases the turbocharger
speed. The boost pressure increased in this way is the reason for the very
high braking effect of the engine. Compared with the retarder, the turbo-
brake provides a weight advantage of about 80 kg.

Retarder
For preserving the service brake system and for an associated
further decrease in maintenance costs, two different retarders are option-
ally available:
• Hydrodynamic high-speed retarder Voith VR 115 A and
• Electromagnetic Telma retarder (BD9).
In daily use the retarders provide the following advantages:
• Up to 90 % of all brake applications can be optimally carried out with
the retarder.
• No overheating of the service brakes even during relatively long periods
of brake application and thus considerably reduced brake wear.
• Doubling of the brake life for the entire truck and trailer combination is
possible.
• Performance stops are possible without using the service brake or
without downshifting.

Steering
1-circuit steering system

The two- and three-axle AXOR and ACTROS vehicles are equipped as stan-
dard with hydraulic 1-circuit power steering.
The steering is integrated into the vehicle diagnostic system and operates
at an operating pressure of 143 bar. This means that malfunctions, such as
lack of hydraulic fluid, for example, are immediately reported to the driver.
Dual-circuit steering system
Four-axle vehicles are equipped with a dual-circuit steering system, i.e. the
steering operates with two independent hydraulic circuits.
When steering, the pressure of the second circuit assists the steering effort
of the first circuit with a pressure of approx. 35 bar.
The hydraulic pressure of the second circuit builds up while driving at a
vehicle speed of 10 km/h.
If one circuit fails, a pressure of 150 bar builds up immediately in the other
circuit and thereby guarantees that the vehicle can be steered even when
loaded. It is thus possible to continue driving to the next Mercedes-Benz
service station without any major problems.
Steering oil reservoir
Two- and three-axle vehicles have a single-chamber steering oil reservoir
that is equipped with an electric oil level indicator.
1 Circuit II steering pressure warning indicator 6 Hydraulic pressure reservoir
Four-axle vehicles have a steering oil reservoir with two separate chambers 2 Circuit I steering oil level warning indicator 7 Circuit II pressure switch
which are also equipped with an electric oil level indicator. 3 Circuit I and II steering oil reservoirs 8 Proportioning valve
4 Radial piston pump 9 Steering gear
The one- and two-circuit steering oil reservoirs are located at the steering 5 Vane-type pump 10 Working cylinder
gear and can be filled when the maintenance flap is open. I Circuit 1
II Circuit 2
01/08 Steering 93
Integral Rear End
The integral rear end offers much greater potential for using the space
behind the cab.
The device carrier with battery and air reservoir is now located in the inte-
gral rear end in the previously unused space between the rear axle and the
end crossmember. The battery is accommodated in a rubber-cushioned
battery box.
At the same time the compressed air drier, 4-circuit protection valve and
trailer control valve have been routed in the frame.
The new location of numerous components means that there is more space
available for a wide variety of add-on units such as larger fuel tanks with a
total volume of up to 1300 liters or for hydraulic pumps, compressors as
well as equipment for complying with future exhaust emission regulations.
The new integral rear end is available for the air-sprung semitrailer tractors
(4x2, 6x2/2 and 6x2/4). For vehicles with the Megaspace cab it is in-
cluded in the standard equipment.
01/08 Integral Rear End 94

"KontAct" electronics concept
"KontAct" electronics concept Main aspects of networking

The "KontAct" electronics concept (Konzeption der Elektronikvernetzung • The networking components are distributed throughout the entire
im Actros, electronic networking concept in Actros) was specifically de- vehicle.
signed for the ACTROS2. With "KontAct", reliability could be further in- • Only a few electronic circuits are located centrally in the electrical
creased and additional functions enabled. Furthermore, with "KontAct" the compartment
CAN bus networking was expanded to the overall vehicle. • The installed components are connected with data lines
In doing so, the diagnostic capability for trucks was also expanded. The • New CAN bus systems have been integrated.
vehicle front and rear end each have their own control module with their • Important tasks in the network have been reassigned to parts in the
own redundant CAN bus. In this way the number of lines and connectors vehicle.
was considerably reduced.
• The functions of the old control units have been distributed to new
"KontAct" additionally makes possible functions known previously only components.
from passenger cars. This includes, e.g. the operation of telephone or radio • Control units have been completely integrated in other components
via the steering wheel buttons. and are no longer present in hardware form but still exist as software;
the diagnostic depth was extended.
01/08 "KontAct" electronics concept 95

Telligent® Systems
The basic idea behind Telligent® systems Overview of Telligent® systems

All vehicle systems are constantly communicating with each other so they can • Telligent® distance control,
operate more effectively. The vehicle systems in the ACTROS, ATEGO, AXOR and
ECONIC are continuously exchanging all important information over the CAN • Telligent® brake system,
data bus. • Telligent® stability control,
The Telligent® technology no longer functions just as a closed system, but • Telligent® engine system,
also as a communications interface:
• Telligent® maintenance system,
All the data from the Telligent systems is constantly available on the CAN bus
system and can be retrieved via interfaces by the body manufacturers. • Telligent® gearshift,
In addition to this is: FleetBoard®, the internet-based telematics application • Telligent® automatic gearshift system,
for fleet management, is based on the Telligent® technology.
• Telligent® level control,
• Telligent® roll control.
• Telligent® Lane Assistant
• Telligent® Active Brake Assist
01/08 Telligent® Systems 96

Telligent® distance control Telligent® shift
The Telligent® distance control ride comfort system is optionally available and The Telligent® gearshift selects the next optimum gear based on a variety of
tracks the traffic at a distance of up to 150 m in front of the vehicle. If the measurement data, such as accelerator pedal position or engine speed.
traffic situation changes, the Telligent® distance control adapts the speed
automatically by braking or accelerating within certain distances (except:
stationary obstacles). Typical areas of application are freeways and multilane Telligent® automatic transmission
Federal highways. The Telligent® automatic gearshift system optionally shifts in a way that great-
ly preserves the material and clutch and "imitates" the shifting style of a pro.
Telligent® brake system
The Telligent® brake system comprises the regulated dual-circuit brake sys-
tem with 10 bar of brake pressure, compressed air disk brakes, ABS, ASR and
additional brakes. The system relays every brake signal at the speed of light.
Furthermore, the Telligent® brake system optimally distributes the brake force
among the tractor vehicle and the trailer or semitrailer, depending on the
loading situation. The Telligent® brake system also ensures that the brake
pads do not wear out unevenly between axles.
Telligent® stability control

The optionally available Telligent® stability control recognizes imminent insta-
bilities and counteracts this tendency - if physically possible. The vehicle also
remains more controllable and more stable during difficult evasive maneuvers
or in hazardous situations.
Telligent® engine system

The Telligent® engine system is constantly provided with all the relevant en-
gine data and calculates from this the optimum injection period and the opti-
mum injection timing point for any driving situation.

Telligent® maintenance system
The Telligent® maintenance system is based on the actual vehicle usage and
therefore permits individual maintenance intervals.
Telligent® level control

With air-sprung vehicles it raises and lowers the frame as required using a
remote control, e.g. for a better adaptation to the loading ramp. Thanks to the
Telligent® level control the vehicle always retains the same height under dif-
ferent loads. This protects the vehicle and increases the ride comfort.
Telligent® roll control

When requested permits a particularly gentle transport of the load and con-
tinuously adapts the shock absorption to the particular driving situation, load
and state of the road through electronic shock absorber control. This also
prevents any rocking or rolling motion and thereby increases driving safety.



Telligent Engine System
The Telligent engine system monitors, controls and regulates the engine.
By constantly adjusting the essential vehicle data, it ensures optimum
engine management. Parameters such as air and boost pressure as well as
oil and coolant temperatures are therefore recorded. Based on this data,
the Telligent engine system calculates the correct timing, the precisely
adapted fuel quantity and the optimal duration of fuel injection for each
individual cylinder.
The Telligent engine system consists of two independent modules: engine
control and drive control. The engine control evaluates all the relevant data
such as fuel injection, load condition, acceleration, etc. and issues the
necessary control commands. The drive control records all the influencing
variables that are crucial for driving mode, such as accelerator pedal posi-
tion, engine brake and acceleration skid control (ASR). Both systems ex-
change the vehicle data via the serial CAN bus system. The engine control
ensures efficient combustion and power output on the basis of the control
data from the drive control – for fuel-saving operation.
The driver receives a corresponding message via the driver information
system (FIS) as soon as an operating condition arises that is critical for the
engine. The cause is displayed on the screen – an acoustic warning also
sounds in critical situations. Adverse effects on operation can be elimi-
nated immediately as a result of the prompt display and resultant damage
may be prevented.
01/08 Telligent Engine System 100

Telligent® Brake System
The Telligent® brake system is based on two pneumatic brake circuits with hill holder
10 bar of constant pressure, which are superimposed by an electronic
closed loop. Travel, pressure and rpm sensors supply the electronics with The Telligent® brake system has a hill holder function that can be activated
data for evaluation in order to optimally utilize the capacity of the 2-circuit and deactivated, which maintains the brake pressure when the vehicle is
air brake system. This permits short braking distances and increased safety stationary. The clutch, brake or accelerator pedal must be pressed slightly.
in road traffic. The system is fitted as standard with ABS, it is available with The brake is not released until when starting off.
ABS and ASR as special equipment. Active Brake Assist
With the Telligent® brake system the brakes respond rapidly. The actua- The Active Brake Assist (ABA) is a support system that in critical situations
tion of the brake pedal is recorded electronically and transmitted to the can help to minimize the risk of a rear-end collision with a preceding vehi-
control unit as a deceleration command. The control unit determines the cle or reduce the consequences of an accident. The driver does not notice
optimum specified pressures for the particular driving and load situation for the system outside such critical situations.
the front axle and rear axle brakes. The result is forwarded to the pressure Active Brake Assist is only offered as special equipment for ACTROS2 in
regulator modules. combination with adaptive cruise control (ART).
The pressure regulator modules convert the specified value requests into If there is a risk of a rear-end collision, the driver is warned by means of a
actual brake pressures and apply these in the wheel brake cylinders. The warning tone and a warning symbol in the display. If the driver fails to
results are rapid response times, short braking distances and therefore respond to the warning, the vehicle is gradually decelerated in stages,
crucial safety advantages. The brake pedal force to be applied by the driver initially by means of partial braking which is then followed by emergency
is comparable with that in a passenger car. braking.
If the semitrailer brake is correctly adjusted, the Telligent brake system
ensures that there is an adjustment of the braking power between the
tractor vehicle and the semitrailer.
The regulating functions in the Telligent® brake system consist of antilock
brake system (ABS) or antilock brake system (ABS) and acceleration skid
control (ASR), depending on the version. Regardless of the road surface,
ABS prevents the wheels from locking at speeds of walking pace and hig-
her. This keeps the vehicle stable and steerable. ASR improves the traction
of the drive wheels, particularly when starting off, preventing the tires from
spinning on smooth surfaces or on inclines.
01/08 Telligent® Brake System 101

Digital monitoring unit
Instead of the analog tachograph, since October 1st 2005 Mercedes-Benz 3. Workshop mode and workshop card
vehicles with a permissible gross vehicle weight of more than 3.5 t and
coaches with more than 9 seats have been equipped with a digital re- • Is used for the initial activation of the recording device
cording device. • Permits the calibration and programming of the digital recording device
No tachograph disk is necessary to operate the digital monitoring unit. (time, date, tire size, K-factor, kilometer reading, VIN, license plate
number, sensor pairing)
A driver card is used for this function. The driver cards must be obtained
from the technical monitoring locations (e.g. Technical Inspection Associa- • Permits the download of data from the recording device or driver cards
tion, Dekra) or from the Federal Office for Motor Vehicles. (software update)
Different cards are available and must be used depending on the operating
mode and authorization. 4. Control mode and control card
• Permits the readout and printing of data from the recording device or a
1. Driver mode and driver card driver card.
• If used for driving mode, contains data on the driver's identity and the • Permits the downloading of data from the recording device or a driver
displayed language. card.
• The card makes the storage of the driver's activity data possible. • With the control card recent events (e.g. manipulations, exceeding
speed limit) can be called up on the display itself.
2. Company mode and company card
• Display, printout, download of the monitoring unit data. The data can be Mass storage device
locked against access by other companies. (important for leased and The following data can be stored in the mass storage device
used vehicles) • Data of the vehicle unit and the speed sensor
• Calibration data
• Daily kilometers for at least 365 days
• Speed at every second, for at least the last 24 hours
• Driver activity for at least 365 days
• Event data: Exceeding speed limit, safety violations
• Malfunctions
01/08 Digital Recording Device 102


01/08 Digital Recording Device 103

Maneuvering, Tow-starting and Towing
General notes Vehicles with Telligent® automatic gearshift system

• When the front axle is raised, do not turn the key in the steering lock • Turn the key in the steering lock into the driving position
into the driving position. • Engage the 3rd or 4th gear. The engaged gear must be shown in the
display
• The front coupling jaw is only provided for maneuvering, tow-starting
and towing. • Tow-start the vehicle. The towing speed may not exceed 20 km/h
• On reaching an adequate towing speed, release the clutch pedal and
• Use a tow bar for tow-starting and towing. operate the foot throttle actuator
• Only tow-start vehicles when the batteries are connected.
The engagement of the clutch is influenced by the actuation of the foot
When towing, if possible leave the engine running so that the power steer- throttle actuator:
ing is working, the oil supply in the transmission is ensured and the brake • When the foot throttle actuator is pressed lightly, this eases in the
system is supplied with compressed air. Release the spring-loaded actuator clutch
of the parking brake mechanically or pneumatically if there is no reservoir • When the foot throttle actuator is pressed heavily, the clutch is en-
pressure in the compressed air system. gaged rapidly
Tow-starting A warning buzzer will sound if the permissible engine speed is exceeded. In
this case select a higher start-off gear or reduce the tow-starting speed
When tow-starting, the key in the steering lock must be in the driving posi-
tion. Vehicles with hydraulic/pneumatic or manual gearshift system:
Vehicles with Telligent® gearshift • Depress clutch pedal fully
• Depress clutch pedal fully • Engage the 5th or 6th gear
• Engage the 3rd or 4th gear. The engaged gear must be shown in the
display
• Tow-start the vehicle. The towing speed may not exceed 20 km/h
• On reaching an adequate towing speed, release the clutch pedal and
operate the foot throttle actuator
01/08 Maneuvering, Tow-starting and Towing 104

Towing Towing in the event of rear-axle damage
Towing in the event of engine damage Notes:
For all-wheel drive vehicles the transfer case must be shifted to the on-road • Before removing the drive shafts, turn the key in the steering lock into
position the driving position
• Switch on the differential locks
• Shift the transmission to neutral
• If a propeller shaft is installed, the vehicle may only be towed a maxi- • Do not raise the front axle
mum of 1 km • For vehicles with two driven axles, remove the axle shafts at the two
• At faster towing speeds and distances of greater than 1 km the propel- rear axles.
ler shaft to the drive axle must be removed
• For all-wheel drive vehicles also remove the propeller shaft between the
Towing in the event of transmission or transfer case dam- front axle and the transfer case
age • For the rear axles HL 7 and HD7 drain the oil from the planetary gears
• Remove the propeller shaft(s) to the drive axles before removing the axle shafts. For a towing distance of more than
100 km the planetary gears must be refilled after removing the axle
shafts
Towing in the event of front-axle damage
• When the front axle is raised, the key in the ignition lock must not be
turned into the driving position
• Raise the front axle. Four-axle vehicles may only be raised when unla-
den.
• Follow the towing instructions as for engine damage
• For all-wheel drive vehicles remove the propeller shaft between the rear
axle and the transfer case
01/08 Maneuvering, Tow-starting and Towing 105

Vehicle Data Card
In order to find workshop information on vehicle repair and maintenance

work, information on the vehicle model series and vehicle model designa-
tion is required.
This information can easily be found through the vehicle identification
numbers (VIN).
The vehicle identification number is located on the vehicle. It is stamped
into the model plate, which is located on the right B-pillar of the vehicle in
newer vehicles and also into the vehicle frame.
The vehicle identification number is also noted on the vehicle data card.
Type plate
The data card can be called the vehicle's birth certificate.
A copy of the data card is usually located in the vehicle together with the
service booklet. An electronic copy of all data cards is also stored in the
Electronic Parts Catalog (EPC).
The entire vehicle data needed for the procurement of replacement parts
and repair of the vehicle is stored on the data card.
Note:
As of 01.09.2005, the data card is no longer glued into the service booklet.
Now, all of the necessary data shown in the vehicle data card can only be
requested via EPC and WIS.
Data card
01/08 Vehicle Data Card 106

Fill out the empty fields!
Vehicle ident. number Tire manufacturer Paint number
Engine number
Sales designation
Transmission number
Special equipment Equipment number
01/08 Vehicle Data Card 107

Overview of Design Groups
KG Assembly KG Assembly
00 Overall vehicle/maintenance 30 Throttle control, cruise control systems
Complete engine, crankcase ventilation, cylinder head, 31 Frame, trailer operation

01
cylinder crankcase 32 Suspension
03 Crank assembly 33 front axle
05 Engine control 35 rear axle
06 Fuel cell system 40 Wheels, chassis alignment
07 Mixture formation 41 Propeller shaft
08 Electric drive 42 Brakes - hydraulic and mechanical systems
09 Air intake, turbocharging 43 Brakes - pneumatics and auxiliary brakes
13 air compressor, belt drives 46 Steering
14 Exhaust manifold, engine brake, emission control system 47 Fuel system
15 Electrical system engine 49 Exhaust system
18 Engine lubrication, engine oil cooling 54 Electrical system, equipment and instruments
20 Engine cooling 55 Additional drive systems, hydraulic and articulation systems
22 Engine mount 57 Central lubrication
23 Special equipment 58 Tools
25 Clutch 60 Body, general
26 Manual transmission 61 Substructure
27 Automatic transmission 62 Front end and firewall
28 Transfer case 63 Side Wall
29 Pedal assembly 64 Rear panel and rear end
01/08 Overview of Design Groups 108


KG Assembly
65 Roof
67 Windshields and windows
68 Interior equipment
72 Doors
77 Sliding roof, soft top, mountings
Central locking, convenience feature,
80 drive authorization systems
82 Electrical system - body

83 Climate control
Emergency equipment, disability equipment, sanitary equipment,
86
kitchen
88 Detachable body components, outside flaps
91 Seats, bunks, restraint systems
94 Body noise, noise damping
97 Body sealing, corrosion protection
98 Paintwork
99 Publications
01/08 Overview of Design Groups 109

Workshop Information System WIS net
The Workshop Information System (WIS) is an advanced, EDP-supported

information system.
It not only replaces the existing workshop literature that had previously
been available as a hard copy and on microfilm, but offers a variety of
options for effectively obtaining the requested information.
With the "Workshop Information System (WIS)", Daimler AG wants to elec-
tronically improve the availability and usefulness of the workshop literature
(e.g. repair, maintenance, basic data, circuit diagrams and in part also the
organization of the literature) of the Mercedes-Benz and smart products by
optimizing the access and through a new design.
In the process, WIS also has an integrating effect to neighboring areas of
activity such as the determination of work units or flat rates via ASRA
(operation texts, standard texts, flat rates and work units) and damage
coding on a workstation.
The following criteria were taken into account:
• Advanced, electronic information system to replace the media micro-
film and paper.
• Faster search and display of literature.
• Simplification of literature search.
• Simple system operation.
• Option to access vehicle-specific data (vehicle data card of the EPC
system).
• Finding vehicle-specific literature.
• Simplification of warranty processing due to integration of damage
coding in WIS.
• Access to literature through the operation no.
• Determining work units or flat rates via ASRA.
01/08 Workshop Information System WIS net 110
The system offers:
• Increased productivity and speed when performing a literature search
and thus shorter waiting times for the workshop personnel.
• Operation via the mouse or the keyboard.
• Automated literature search.
• Damage coding (for warranty processing).
• Opening the vehicle data card from the EPC system with the full code
designation written out.
• ASRA data, basic documentation for creating orders, invoices and
warranty claims.
• Dynamic, vehicle-related creation of service sheets with an interface to
ASRA.
01/08 Workshop Information System WIS net 111

Meaning of Symbols in the Workshop Literature
Symbols for work notes

Symbol Designation Symbol Designation
D Warning, danger J Check
S Property damages M Filling capacities
L Note/information N Standard tools
F Disassemble O Special tool
E Assembly Q Torque
H Remove P Cleaning
G Install R Measure
I Measure with meter
01/08 Meaning of Symbols in the Workshop Literature 112

Symbols for types of literature
Symbol Designation Symbol Designation
D Diagnosis R Special waste handling
E Fault information T Administration, application directories, etc.
F General information U Wiring diagrams of electrical system
G Retrofitting V Circuit diagrams for hydraulic components
H Maintenance and care W Circuit diagrams for pneumatic components
I Testing and repair work X New features/modifications
% Tightening torques Y Service measures
J Operating fluids Z New introduction
K Test/adjustment values [ Workshop device
L Filling capacities ] Commercially available tools
M Repair materials \ Shop-made tools
N Technical modifications $ Special tool
Q Functions, as-built configurations
01/08 Meaning of Symbols in the Workshop Literature 113

Xentry TIPS
XENTRY TIPS is a comprehensive data processing system for the worldwide

exchange of technical information via the Internet. It supports product
support, product quality tracking, technical service in the workshop and
24 h service.
XENTRY TIPS is mainly used as a support for warranty and goodwill cases
and contains current information that can be very helpful during trouble-
shooting and for eliminating faults.
The information is divided based on product groups. The current topics can
be quickly found based on symptoms, which are divided into different main
groups, or, as known from WIS net, via the design groups.
When the VIN is entered, the search can be limited to documents that
apply to the vehicle.
Sometimes documents contain measures on how to proceed in the event
of warranty work. If the recommended measures are not observed, it is
possible that the warranty work that has been performed is only accepted
in part or not at all. Therefore it is recommended to check in XENTRY TIPS
before starting with any warranty work, whether the corresponding infor-
mation is available for the current complaint.
Documents the user has opened some time ago are listed under the tab
"My searches" and can quickly be found when they are needed again.
The documents are stored in PDF format and can be downloaded from
XENTRY TIPS and printed out.
01/08 Xentry TIPS 114

TIPS documents can contain data on document numbers, part numbers,
operation items and damage codes. In the future, it will be possible to
transfer this data directly from XENTRY TIPS to EPC net or WIS/ASRA net.
Further functions are being planned:

• Launch of EPC net and WIS/ASRA net from the Xentry TIPS main navi-
gation
• Transfer of data from a TIPS document to EPC net and WIS/ASRA net
• Online access to vehicle data from the FDOK
Advantages:
• Increase in aftersales expertise in the workshops, markets and in CAC
Maastricht and thus greater customer satisfaction.
• Increase of economic viability through
- Reduction in diagnosis and repair times.
- Improvement in data quality for the field information.
- Reduction of the warranty and goodwill costs since key damage top-
ics and their remedies can be detected early on
- Reduction of incorrect removals/repeated repairs in the workshop.
• Improvement in product quality, thereby supporting the brand image.
Important!
Some TIPS documents contain information on procedures for fault rectifi-
cation of – for the most part current - warranty and goodwill cases. If the
prescribed procedure is not observed, it is possible that the refund of costs
for the service operation will be rejected.
Therefore, always check in XENTRY TIPS before starting warranty & good-
will work, whether there is any current information on fault rectification.
01/08 Xentry TIPS 115

Electronic Parts Catalog
The Electronic Parts Catalog (EPC) is an electronic system for parts identi-
fication.
• The EPC contains the parts literature of the established product
ranges from commercial vehicles, passenger cars, major assem-
blies as of approx. 1962
• The EPC contains the vehicle data card for vehicles and major
assemblies as of approx. 1978
• The EPC provides connections/interfaces for various data proc-
essing systems (Dealer Management Systems).
• The EPC provides the vehicle data card for the Workshop Informa-
tion System (WIS).
• In the particular EPC system that is installed, the scope of brands
and categories (assortment classes) as well as
the number of users depends on the license code.
• The EPC can be operated with the mouse or via the keyboard.
01/08 Electronic Parts Catalog 116

The replacement part numbers at Mercedes-Benz are divided into different
code letters.
A Design part number
N Standardized part number
Q DIN parts
W Special tools
B6 Accessory parts
The replacement part number is represented as follows:

O 210 410 9306
Exact part
Change number
Design group (propeller shaft)
Vehicle model (model 210)
Design part number
Exercise:
What does it mean, when the first 3 numerals of a part number are To which design group does this replacement part belong?
between 000 and 099?
D It is the model series designation of the original vehicle model. 210 545 0215
E It is a right-hand drive vehicle. This replacement part belongs to group 54 (electrical system: instrument
equipment)
5F The component is generally used, in other words it is not
model-specific.
01/08 Electronic Parts Catalog 117

Damage Code
The damage codes are called up via the WIS net main menu.
Based on the VIN that has been entered, all damage-relevant assemblies of
the vehicle and its components are listed by design groups.
Using the various selection options, the corresponding damage code can
be quickly found.
The damage code is made up numerically from the following:
• the damage ID
• the damaged part
• the damage type
• and the repair type
01/08 Damage Code 118

Online Vehicle Documentation System - FDOK
FDOK (Fahrzeugdokumentation Online - online vehicle documentation System access from NET/MASTER
system) is the central documentation system by Daimler AG for all Mer- The access from NET/MASTER described in the following applies to users
cedes-Benz model series. All vehicles delivered since 1982 are docu-
at the head office and in the field organization of the DaimlerChrysler Sales
mented in FDOK in the condition they have left the manufacturing plant.
Organization Germany.
FDOK is currently being used worldwide by approximately 25,000 users After switching on the data viewing device or opening the PC application
within the Mercedes-Benz organization via online access. This is mainly 'Rumba', the NET/MASTER main screen appears.
supported by the fact that, as an option, user interfaces are also available
in English, French, Italian, Portuguese and Spanish in addition to the Ger-
man user interface.
System contents
The following information on each vehicle is stored and can be called up
online in FDOK:
• Vehicle-specific data, in particular the serial number of the individual
major assemblies
• Packages, broken down by codes and special equipment numbers, with
a contextual description
• Sales, certification and service-relevant data (including model plate
data)
• Vehicle-related text fields where any text can be entered for different
user groups
• Documentation of changes to the as-built configuration on the
major assembly, code and special equipment number level
• Data required for flashing or coding of control units Entry:
User ID (for USER)
• Theft information on vehicles reported as stolen Password (for PASSWORD)
Data release
01/08 Online Vehicle Documentation System - FDOK 119

After the entry has been made, the NET/MASTER selection screen The FDOK access screen appears.
(Multiple Application Interface Menu) appears:
Entry: Entry:
6 for FDOK (in this case) User ID (for USER ID)
+ data release Password (for PASSWORD)
+ data release
or s in the line with FDOK
+ data release Next, the screen 0000 appears (FDOK main menu).
Next, the IDMS screen appears, on which the preferred language version
must be specified.
Entry:
fdok German
or fdoke English
or fdokf French
or fdoki Italian
or fdokp Portuguese
or fdoks Spanish

General structure of the FDOK screens
All FDOK screens have a standardized framework (lines 1 - 2 and 22 - 23).
Line 1: Number and designation of the selected screen
Line 2: NFC: Input field for the direct selection of another screen
VKZ : Input field for the processing character (to be filled out only when
required)
Each screen can be accessed in the normal screen sequence or directly
selected by making an entry in the
NFC (= Next Function Code) field. For this purpose, the 4-digit function
code of the target screen must be entered left justified and confirmed
through data release in the NFC field.
The following table contains a list of all FDOK passenger car screens with
their function codes:
This screen contains the most important vehicle production data as well
as all special request codes.
The individual lock numbers and the radio code number can be called
up, when an 'x' is set in the selection field (‘_’) behind the relevant field and
data release is pressed.
In the process, the system creates a record whenever a lock system
number is called up!
While the radio code number can be called up by any user, calling up the
lock number (up to DAS [FBS] 2b) and the mechanical object number (DAS
[FBS] 3) is only possible for authorized users.
The electronic object number (DAS [FBS] 3) can only be called up by users
of the specialist department .
Note: Commercial vehicle screens start with a 1 (e.g. 1111 basic data)


Specifications for Operating Fluids
Operating fluids (e.g. engine oils, automatic transmission fluids, hydraulic The Specifications for Operating Fluids are divided into main groups and
fluids, greases, anticorrosion/antifreeze agents, brake fluids) are just as into corresponding subgroups.
important for the operation and service life of vehicles as the actual vehicle
parts.
There are the following main groups:
Consequently, Daimler AG subjects these products to meticulous examina-
tion and testing. • Fuel directory Sheet 100
If a product submitted to Daimler AG displays the specified properties, it • Lubricant directory Sheet 200
can be approved for use and included under its brand name in the Mer-
cedes-Benz Specifications for Operating Fluids. • Directory for further operating fluids Sheet 300
The brand name on containers and in sales literature must correspond

exactly to the brand name printed on the approval certificate. The subgroups e.g. for lubricants are divided as follows:
The use of approved operating fluids forms an integral part of the warranty • Engine oils Sheet 220
terms and conditions.
• Transmission oils Sheet 230
The Specifications for Operating Fluids are stored in the Workshop Informa-
tion System (WIS). • Lubricants Sheet 260
01/08 Specifications for Operating Fluids 123

Exercise:
Complete the table below by looking up the specified sheet numbers for
engine oils in the Workshop Information System!
Passenger Sheet number Sheet number

Truck
vehicle
engines
engines
M 166 229.1; 229.3; 229.31; 229.5 BR 400 228.0; 228.1; 228.2; 228.3; 228.5
M 271 229.3; 229.31; 229.5 Model series 500 228.0; 228.1; 228.2; 228.3; 228.5
M 275 229.3; 229.31; 229.5 BR 900 228.0; 228.1; 228.2; 228.3; 228.5
M 285 229.5 Gas engines 228.0; 228.1; 228.2; 228.3; 228.5
Diesel engines
OM 646 228.2/3; 228.5; 229.3; 229.31; 229.5 with particulate 226.9
filter
OM 647 228.2/3; 228.5; 229.3; 229.31; 229.5 229.31
OM 648 228.2/3; 228.5; 229.3; 229.31; 229.5
01/08 Specifications for Operating Fluids 124

Work units
Operation texts and work units make communication between the customer Customers, service forepersons/service advisers, mechanics, as well as the
of the MB workshop and Daimler AG easier. entire dealership benefit from using the operation texts and work units.
They create a connection between the customer, the MB workshop and Daim- Daimler AG prepares operation items for the repair work necessary in the
ler AG. Standardized handling and direct paths ensure a smooth information workshops.
flow. The operation items comprise operation texts and work units (domestic) or
standard texts and flat rates (abroad).
Customer
Operation texts and work units
Factory
Workshop Customer service

reception
01/08 Work units 125

Basic and allowance time
Flat rates
Basic time Allowance time
• Purely productive working hours on the vehicle or

major assembly, personal operative
• perform work procedures as per the maintenance
and repair guidelines. • Brief cleaning, • Receipt of orders,
• personal needs, • parts procurement,
• rest period, • maneuvering,
• changing work clothes. • brief information,
• paperwork (repair/extended order, processing),
• tools procurement,
• supervisory work,
• cleaning up workplace and rough cleaning.
Note
ZM: (Time prescribed by foreperson) Work units are execution times determined through time studies for the
scope of work specified in the operation text.
Applies to work operations with an expenditure of time that cannot be They are specified in the work unit.
defined through work studies, e.g. preparing, repairing, or restoring
movability. 1 work unit flat rate corresponds to 5 minutes; 12 work units make
These work units must then be defined and specified by the foreper- 1 hour.
son.
This also applies to operations for which work units have not been The evaluation of the time studies results in a flat rate for the completion
specified or that differ from the prescribed scope of work. of the work operation.
This flat rate is made up of the (normalized) basic time and the operative
and personal allowance time (basic time and allowance time).

Work unit components
Stand-alone operation
(e.g. 15 work units) = Basic time
(10 work units) + Allowance time
(5 work units)
As an individual
order
e.g.
Allowance time portions in the example personal and • Get repair
productive
remove/install exhaust system operative order,
In combination with • Maneuver
other repair orders vehicle.
Technically linked operation

(e.g. 12 work units) = Basic time
(10 work units)
+ Allowance time
(2 work units)
Not applicable
Note
The stand-alone operation starts with the mechanic accepting the The allowance times for technically linked operations are shorter, since
repair order and ends with handing it over to another mechanic or to minor work such as getting the order, bringing the vehicle into the work-
final inspection. shop and getting tools ready are already included as an allowance time in
the basic operation.
The technically linked operation is also a complete work operation;
however, it is performed in combination with another operation.

Advantages of operation texts and work units
The particular advantages of using operation texts and work units, from the
perspective of the customer, the mechanic, the dealership and the
service adviser.
Service foreperson
Customer Mechanic MB dealer
service adviser
• Professionalism: • Clarity: • Economic viability: • Gain of time:

standardized work description in standardized terms, professional order processing clear order wording, fewer fur-
Mercedes-Benz dealerships, and invoicing, ther inquiries,
• Gain of time:
• Planning safety: less need for further inquiries, • Utilization of workshop capac- • Transparency:
precise completion date, ity: exact cost calculation possible,
• Justice:
sound advance planning of ap-
• Reliability: verifiably adequate • Coordination:
pointments,
appointments are reliably kept, work distribution, sound appointment planning
• Precondition for invoicing: through work units,
• Trust: • Clarity:
of warranty and goodwill claims
realistic cost estimate, standardized work description in • Simplification:
with DC production plants,
all Mercedes-Benz dealerships. final inspection made easier,
• Credibility:
• Clarity:
order text and invoice text • Work organization:
order text and invoice text
match. less paperwork.
match.

Operation number structure
01 2401 03 Remove/install engine with manual transmission
01 2401 Determines the operation text
01 Design group
2401 Operation number
03 Line number
If there are deviations from the typical scope of an operation item (more time needed e.g. in the event
01 2401 99 of complications), e.g. line number "03" is replaced with "99". The working hours that are actually being
spent are specified by the foreperson.
If no matching text or operation number is available for an operation as a microfiche or in the ASRA, an
01 0000 99 operation number is created as described earlier.
The design group must be specified at any rate.

ASRA
ASRA is an electronic work unit/flat rate catalog, which makes it possible
to find out operation items, working hours and damage codes quickly and
reliably.
Data found out with ASRA forms the basis for the generation of orders,
invoices and warranty claims.
ASRA will replace the use of microfiche step-by-step.
Data stock:
• Operation texts or standard texts, included work texts, notes.
• Work units or flat rates.
• Pictures (sketches or schematic diagram of vehicle components).
• Damage codes for warranty processing.

Maintenance
Whenever a machine is running, including motor vehicles, there will be Time-based servicing
wear.
The maintenance can take place at regular intervals. A time-based servicing
This can be, e.g. abrasion of material such as on brake and clutch linings, scheme is selected, regardless of whether or not the vehicle is being oper-
decomposition of lubricant such as in engine oil or deposits of material in ated.
the air filter or oil filter. An example for a time-based servicing scheme can be the exchange of the
brake fluid, which is exchanged every two years in Mercedes-Benz passen-
ger cars and vans.
A change in material properties is also considered to be wear. Brake fluid
for instance is hygroscopic (water-absorbing), thus resulting in an in- A time-based servicing scheme is also selected, when the vehicle is rarely
creased hazard potential: used. In this case, the chemical decomposition or aging of materials con-
tributes to a greater extent to the wear than the wear caused by use.
• Brake fluid is heated in the brake caliper under corresponding driving
Typically, the vehicle should be taken to the workshop for servicing at least
conditions,
once a year, even if the specified driving distance has not yet been rea-
• water vapor bubbles are forming in the brake fluid, ched.
• water vapor gives in under the brake pressure,
• brake pressure cannot be built up.
Maintenance based on the driving distance
When the vehicle is frequently used, maintenance is typically based on the
These wear processes make periodic maintenance necessary, during which driving distance. It reflects the use of the vehicle and thus the wear of its
the affected components, lubricants or fluids are exchanged. parts.
The exchange of lubricants, fluids and filters as well as checking wear parts It is selected in each case after a certain driving distance has been trav-
are within the maintenance scope. eled.
Care measures and repairs are not part of maintenance. However, the maintenance based on the driving distance is only an ap-
proximate measure. Only the wear while driving is registered, but not the
wear that takes place when only the engine is running, e.g. during stop and
go or when the vehicle is used as a working machine.
01/08 Maintenance 131

Maintenance as per customer request
Maintenance can also be performed regardless of the requirements upon
customer request, e.g.
• before going on a longer trip,
• before or after a change of the registered holder of a vehicle.
Resource
Resources are the operating material reserves that are available such as
engine oil, brake pads, etc. 100%
Wear consumes the resources. If the resource has reached zero, service is
due.
Resource
During service, the resource is always replenished to become 100 %.
The speed with which the resource is consumed depends on the extent to
which the vehicle is used.
Example:
Commercial vehicles in construction site traffic are exposed to high loads 0%
due to dust and dirt; the drive assemblies are heavily stressed. Although Time, driving distance
this is not reflected in the mileage, the resources are consumed more Maintenance interval
rapidly. Maintenance Maintenance
On the other hand, the lowest loads result from long-distance haulage. Due
to the consistent loads the vehicle is exposed to and the long driving dis-
tances, fewer resources are consumed in spite of the high mileage.
The driving style also has an impact on the consumption of resources.
Consistent, preventive driving results in a lower consumption of resources
than a sporty driving style.

At the moment, almost all Mercedes-Benz vehicles are equipped with a Flexible maintenance systems
flexible maintenance system.
The maintenance system ensures that the resources are used to the great-
In vehicles without maintenance system, specified maintenance intervals est extent possible depending on the severity and type of use of the vehicle
are used. with the help of measuring systems.
In the process, the anticipated maintenance period is always extrapolated.
The maintenance intervals consist of the following: The required maintenance is displayed in the instrument cluster in due time
before it is due.
• Care service (engine oil and filter change),
• Maintenance service In passenger cars, the maintenance system uses a series of measuring
such as care service, but also additional operations, such as lubri- gauges to mainly monitor the engine.
cation work, fill level checks, function tests, additional operations The wear of the brake linings is also determined (ASSYST PLUS).
depending on the maintenance schedule of the vehicles. In commercial vehicles, the measurements are performed in a differenti-
ated manner by major assemblies. As a result, separate maintenance of the
major assemblies and thus the best possible use of resources is possible.
In the event of rigid maintenance intervals, the maintenance operations are At the same time, the operating costs of the vehicle are reduced.
due when a certain driving distance or a specified time has been reached.
Disadvantages of rigid maintenance intervals:
• Resources are frequently not exhausted,
• Resources are consumed prematurely in isolated cases.

Tasks:
1. Which operations are part of maintenance? 3. Which statement regarding flexible maintenance is correct?
Aa Oil change. A a The due date for the maintenance is displayed in the instrument
cluster.
b Exchange of the vehicle battery. b The customer is free to select the maintenance period.
c Cleaning of the vehicle. C c Flexible maintenance makes full use of the resources.
d Exhaust repair. d Maintenance is no longer required.
2. Which types of maintenance are there? 4. Which statement regarding the rigid maintenance interval is correct?
Aa Maintenance as per customer request. a The customer must decide on a time-based servicing scheme or
maintenance based on the driving distance when purchasing the
Bb Time-based servicing scheme.
vehicle.
Cc Maintenance based on the driving distance B b The resources are not fully exhausted in some cases.
d Legally prescribed maintenance.
c The customer is limited to fixed dates when making an appoint-
ment.
D d The resources are consumed prematurely in some cases.

ASSYST
General Oil change reset triggered inadvertently

With the "Active Service System" (ASSYST), the driver is made aware of a If an oil change reset was triggered at the instrument cluster or using STAR
due service. DIAGNOSIS, although no oil change was performed, this must be undone
immediately.
The ASSYST system is a demand-based engine oil service system. This
means that in addition to purely time and distance criteria, various factors A corresponding menu is available in STAR DIAGNOSIS for this purpose.
are taken into account when calculating the service intervals that are ba-
sed on need.
On the one hand, these are quality factors which are coded using STAR
DIAGNOSIS, on the other hand, assessment factors which take into ac- Influencing variables
count driving conditions and therefore the actual wear. Assessment factors ((depending on the actual driving conditions):
The "Active Service System" ASSYST is used in the Vito and in the Sprinter.
• load moment,
• rotational speed,
Display • oil level,
In the multifunction display of the instrument cluster, the service interval is • engine oil temperature,
displayed in the text boxes together with the service symbol when re- • oil correction factor (serves as a comparative value for determining the
quested by the driver or automatically when exceeding a warning threshold oil level),
in the form of the remaining distance or remaining time.
• coolant temperature.
Engine oil monitoring

Information regarding the actual status is displayed in the multifunction
display in case of oil starvation or overfilling. A bonus is awarded for oil
refills, thereby extending the service interval.
01/08 ASSYST 135

Quality factors Remaining distance.
The quality factors are factory preset to basic values and can be altered The remaining distance is the distance remaining between the current
using STAR DIAGNOSIS, if the usage conditions necessitate this. The qual- kilometer reading and the next service.
ity factors influence the starting distance. The remaining distance is at least as long as the starting distance, but as a
maximum twice as long as the starting distance.
Right after an oil change, the remaining distance is equal to the starting
Starting distance.
distance.
The starting distance refers to the minimum service interval in kilometers,
The remaining distance is dependent on the following factors:
which can be driven up to the next service.
The starting distance depends on: • Starting distance
• Driving conditions
• Engine variant: Gasoline engine/diesel engine.
• Oil refilling in vehicles with oil sensor
• Country of use: The mileage is coded in accordance with the national
version. Thus, the driving conditions are also taken into account in ASSYST.
• Mileage: ASSYST receives the wheel speeds from the
traction system control unit (ABS/ESP) via CAN for calculating the mi-
leage.
• Time: ASSYST receives the time information from the clock integrated
into the instrument cluster.
The starting distance is not dependent on the driving conditions or oil
refilling.
01/08 ASSYST 136

Telligent® Maintenance System WS
The maintenance system WS is an electronic system that considerably in- The maintenance system includes:
creases vehicle economy by reducing the manual vehicle inspections, the
service requirements and the vehicle downtime. • Determination of usage-related maintenance intervals,
The maintenance system is incorporated into the instrument cluster function • Planning of individual service dates for maxi-
and uses the controls for internal on-board operation. mum utilization of the operating fluids (individual service),
The instrument cluster display serves as the display element. • Planning of integrated service dates in a selectable time period to
reduce workshop visits (integrated service),
The maintenance system control unit is connected to all the connected elec-
tronic systems in the vehicle via the CAN data bus. • Grading of displays for due service dates into three levels according to
In addition to the information made available via the CAN bus, the mainte- the urgency (advance warning, due, and overdue),
nance system also uses the signals from maintenance-specific sensors. • Monitoring of various operating ranges with the display and partial
It is possible to access the maintenance system data via the diagnostic socket storage of unusual operating conditions and system errors,
using Star Diagnosis. • Display of the outside air temperature,
• Display of the vehicle operating hours.
01/08 Telligent® Maintenance System WS 137


01/08 Telligent® Maintenance System WS 138

Special Service Procedures
Actros Vito, Sprinter, Vario

• Coolant • Coolant
Check once a year for its corrosion inhibiter/antifreeze concentra- Check once a year for its corrosion inhibiter/antifreeze concentra-
tion and correct, preferably at the start of the cold season. Replace tion and correct, preferably at the start of the cold season. Replace
the coolant every three years. the coolant every three years.
• Brake fluid • Brake fluid
Replace in the clutch operating system and the hydraulic power Replace in the clutch operating system and the hydraulic power
shift every three years, preferably in the spring. shift every three years, preferably in the spring.
• Dumper oil • Dumper oil
Change once a year, preferably at the start of the cold season. Change once a year, preferably at the start of the cold season.
• Compressed air drier • Compressed air drier
Replace the granulate cartridge every two years. Replace the granulate cartridge every two years.
• Wheel hubs of front axle, leading axle, trailing axle • Wheel hubs of front axles
Replace grease every two years, inspect tapered roller bearings. Replace grease, inspect tapered roller bearings. (see maintenance
Use prescribed grease. sheet)
Not applicable to vehicles with compact bearing.
• Air filter element
• Air filter element Replace every three years. Note installation date.
Replace every three years. Note installation date.
• Poly-V belt
• Range-change transmission Replace every six years for models:
Clean the oil strainer at the first service 638
901.0/3/4, 902.0/3/4, 903.0/3/4, 904.0/3/4
01/08 Special Service Procedures 139


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Trucks • Overall Vehicle STAR

DIAGNOSIS Basic Training

t Issue date 01/08

1511 6146 02 - 2nd edition 01/08 144

Page Title Page Title

Welcome to the basic training course entitled

Certified diagnostic technician

Maintenance technician (WT)

Services Other activities

• In 1966, Maybach became a subsidiary of the Daimler Benz AG.

Möhringen in 1990 Möhringen in 1920

Mercedes and Mercedes-Benz technologies that made history

1927 Mercedes-Benz L 5: First six-cylinder diesel truck.

01/08 The Technical Milestones 12

01/08 The Technical Milestones 13

01/08 The Technical Milestones 14

01/08 The Technical Milestones 15

Model designa- Weight class

Vito/Viano (639.6 - 8) Vaneo (414.7)

01/08 Overview of Light Vans 17

Itemization of the chassis numbers Mercedes-Benz commercial vehicles

Axor (940 - 944) Axor (940 - 944)

The table is not necessarily complete.

01/08 Overview of Commercial Vehicles (excerpt) 18

Actros (930 - 934) Actros (930 - 934) Econic (957.0..)

Other commercial vehicles in the Daimler group of companies

Mitsubishi Canter Travego Western Star Sterling Trucks

01/08 Overview of Commercial Vehicles (excerpt) 19

Citaro Capa-City Travego Sprinter Travel

Other buses in the Daimler group of companies

01/08 Overview of Commercial Vehicles (excerpt) 20

01/08 Overview of Commercial Vehicles (excerpt) 21

01/08 Vehicle Versions and Designations 22

01/08 Vehicle Versions and Designations 23

01/08 Vehicle Versions and Designations 24

Mercedes-Benz cabs were designed specifically for the requirements of the

Displacement Rated output Rated torque

M 111 2295 105 215 No Sprinter 901

01/08 Overview of Gasoline Engines 31

01/08 Overview of Gasoline Engines 32

• Four-valve technology with variable, continuous camshaft adjustment

01/08 Overview of Gasoline Engines 33

01/08 Overview of Gasoline Engines 34

01/08 Overview of Diesel Engines 35

01/08 Overview of Diesel Engines 36

01/08 Overview of Diesel Engines 37

01/08 Overview of Diesel Engines 38

01/08 Overview of Diesel Engines 39

01/08 Overview of Diesel Engines 40

01/08 Overview of Diesel Engines 41

01/08 Overview of Diesel Engines 42

01/08 BlueTec Diesel Technology 43

01/08 BlueTec Diesel Technology 44

01/08 BlueTec Diesel Technology 45

In lightweight commercial vehicles a 6-speed manual transmission is ade- Splitter range

01/08 Range-change Transmission 46

01/08 Range-change Transmission 47

Red: Main transmission

01/08 Range-change Transmission 48

Vehicle model Transmission Transmission Transmission

01/08 Range-change Transmission 50

01/08 Range-change Transmission 51

Shift type Mechanical shift Hydraulic shift Telligent Telligent Mercedes