Mercedes Actros III 2008 thru 2011, service e-manual (in Russian)

Content Operation and maintenance Briefly about the Mercedes Actros truck Telligent system Engine and transmission Automated transmission Cabin. Execution options Chassis Main technical characteristics of the Mercedes Actros 1841LS tractor unit Axles and suspension Braking system Frame and frame elements Electrical / electronics Engine and fuel system Clutch and gearbox Wheels and tires Cab Exterior Interior Additional equipment Working fluids, oils and lubricants Vehicle performance specifications Compressed air system Engine Tire pressure Tightening torques for wheel nuts / bolts Spring loaded pneumatic parking brake cylinder NR (Telligent Vehicle Leveling System) Vehicle identification numbers Nameplate with Vehicle Identification Number (VIN) Explanation of designations on the identification plate Engine identification plate VIN decoding Purchasing spare parts Spare parts identification Security General notes on vehicle safety systems Hanging the car on a lift or jack Reinforced points for jack head, lift support or fall arrest legs Maintenance - General Information Compartments for on-board instruments On-board tool kit and emergency equipment Cab rollover Mechanical-hydraulic tipping mechanism Electro-hydraulic tipping mechanism Battery automatic emergency switch Fuses Fuses assignment Check and replace Automatic circuit breaker Telligent Maintenance Monitoring System Introduction Automatic service messages Resetting the maintenance timer Service compartment front cover Opening Closing Maintenance Points - Weekly Checks and Some Routines Coolant level Coolant Coolant additives in warm climates Clutch (torque converter or fluid coupling) Windshield and headlight washer Replacing the wiper blades Engine oil level in the engine Checking the level on the on-board computer display Hydraulic fluid level Battery compartment Batteries Disconnecting and connecting batteries Removal and installation of storage batteries (accumulator batteries) (for example, 4-axle trucks) Service and maintenance Charging the system with compressed air Starting the engine from an external battery, towing and starting the engine from a tug Starting the engine from an external battery Towing and starting a car from a tug Front hitch Rear hitch Starting the engine from a tug Tires and their pressure Tire marking Tire pressure - adjustment Tire Pressure Monitoring System - Calibration Wheels - removal and installation Withdrawal Checking Installation Wheel nut tightening torques Maintenance - Individual Scheduled Operations Engine oil and filter - change Oil in a manual transmission (manual transmission) - replacement Models 710, 712 and 715 without G02 Models 715520 Code G02 (with torque converter) Withdrawal Filling Power take-off oil filter - change Retarder (models with code BA 9) - oil change Clutch Fluid (Models Code GK8) - ATF Change Clutch Fluid (Models Code GK8) - Replacing Oil Separator Filter Transfer case (RK) - oil change Front Axle (4WD Models) - Oil Change Rearaxle for models with one rear axle and second rear axle for models with two rear axles - oil change Oil volume (l) in the front axle and wheel reducers First Rear Axle on Dual Rear Axle Models - Oil Change Fine fuel filter - replacing the filter element Fuel system - bleeding Coarse fuel filter - sludge draining and flushing Eddy current transmission brake (retarder) model Foca l F 3300 (Telma) - clearance check Engine Air Filter with Dust Valve - Dust Removal Engine valve clearances - control and adjustment Clutch air strainer - replace Suspension Threaded Fasteners - Check Tightening Torques AdBlue Exhaust Air Filter - Replace Voit h retarder oil separator filter - change Periodic lubrication (injection of grease fittings) Accessory Drive Belt - Check Condition Exhaust gas emission control system using AdBlue - creating overpressure in the pressure tank Engine Cooling System - Check Coolant Level and Antifreeze Concentration Intake Ducts - Check Condition Tipper hydraulic drive - oil change Cab ventilation dust filter - replace Front Spring Pin - Change Grease Wheel bearings models 934251 with rear axle 749111 - grease change, check and adjust Compressed Air Filter Dryer Cartridge (Models Code B62 - Dual Chamber System) - Replace Hydrostatic drive fan a (rear cooling systems) - oil and oil filter change Engine Air Filter - Replace Standard Air Filter - 541 & 542 Models Engine air filter 541 on models with code M97 or MJ1 Air filter for engines 541 on models with code M62 Air filter for engines 541 and 542 on models with code M49 Engine Cooling System - Changing Coolant and Flushing the System Hydraulic clutch - fluid change Software initialization Gearbox 7155 except for models with code IY2 (hydraulic fluid according to DB 34 list) Gearbox 715ххх with GS3 code ("hydraulic" shift) except for models with code IY2 Dust filter air conditioner and on models with code H09 - replace Individual maintenance operations directly affecting the safety of the P Trailer hitch (saddle) - check for serviceability, secure fastening and absence of backlash Checking Adjustment Models with Jost drawbar Models with GF drawbar model SK-S 36.20 Models with GF drawbar model SK-S 36.22 Leaf and Air Springs - Check Condition Brake Pad Wear Assessment - Reading the Instrument Panel Display Automatic brake control mechanisms (models with drum brakes) - check the stroke of the working cylinders Steering - check status Self dump tipper - check Headlamp direction - adjustment Post-processing of maintenance data on the on-board computer display Control System Overview of the local network of controllers of the control system of units and assemblies of the car Kont Act Electrical and electronic connections of components in the Kont Act car control system Application System Integrated Circuit (ASIC) Subbus Core Module (GM) (A7) Benefits Comprehensive Kont Act Network Collection and registration of data Data exchange Broadcast function (central gateway) Security Strategy An example of the organization of the Kont Act network CAN bus system overview Electronic Control System Components - Description and Location on Vehicle Diagnostic connector - general notes Block (A6) MR engine electronic control system Selective catalytic reduction (SCR) control unit (A95) Flare Launcher (FLA) Control Unit (A4) Block (A16) gear shift control system (GS) General information Registration and evaluation of date signalschikov Registration, evaluation and transmission of CAN messages containing gear shift data Electric activation of solenoid valves when switching on certain gears and when controlling the clutch A63 control unit for autonomous intelligent cruise control (ART) A631 radar sensor control unit Block A3 of the vehicle motion control system (FR) Tasks performed by the block in different modes Models code GS7 (Gear control II) code GE2 (Electronic drive control II), code GE3 (Mercedes Power Shift) or code GE7 (Mercedes Power Shift 2) Models with MD9 (Cruise control) code Models Code ET5 - Adaptive Cruise Control (ART) Brake control (BS) control unit A11 Drive Axle Brake Modulator - Models Code ZX2, EPB II Electronic Vacuum Brake System Drive axle brake modulator - models without code ZX2, brake system without electronic EPB II system With electronic brake control In the event of a malfunction of the electronic system A111 brake control unit Active brake assist (ABA) - models with code BC6 (Active Brake Assist 2) or with code BC7 (Active Brake Assist) A74 control unit for dynamic stability control (FDC) - models with code BB7 (Stability contro l - SR) The principle of operation of the lateral acceleration sensor The principle of the yaw rate sensor A20 unit of the retarder control system (RS) - models with code BA1 (Voit h retarder) General information Registration and evaluation of sensor signals Electrical activation of the unit (Y114) of the solenoid control valves of the retarder Registration, evaluation and transmission of CAN messages B68 Steering Wheel Angle Sensor - BB7 Models (Vehicle Stability Control (SR) Battery disconnect contactor K2 Basic module A7 (GM) Unlocking the cab Radio receivers for remote control of door locks System (NR) trim control (caster angle) Gateway function Power take-offs Diagnostic connector Multifunction steering wheel Editable parameters Headlight range control Communication processor KOM Maintenance System (WS) Central Storage (Data Storage) (ZDS) Klaxon or Typhon Washer and wiper system Cab tipping mechanism Lighting Anti-theft alarm system (ATA) Prevention concept - functions of the front and rear modules in the CAN system Front module A64 unit (FM) Headlights and lanterns Trim (NR) and Roll (WR) Control System Blocking of cross-axle and center differentials, a gearbox in the transfer case of an all-wheel drive transmission Block A65 of the rear module (HM) Taillights Trim (NR) and Yaw (WR) Control Systems Maintenance System (WS) Compressed air supply, compressed air dryer heater, parking brake, fuel tank Tipper tipper / Bordmatik system Inter-axle and cross-axle differential locks, differential gear lock in the transfer case Block A68 of the main switch module Block P2 of the instrument panel module (INS) Tachograph Module P3 Block (MTCO) Lane Assistant (SPA) Control Module A62 Unit - ET7 Models Driver's door component control module (TMF) block A66 Adjusting the position of the exterior mirror on the driver's door Adjusting the position of the outside mirror on the passenger door Driver's door power window control Passenger door power window control On models with an automatic lifting system for sliding windows in the doors Heated exterior mirrors Central locking and automatic closing Self-diagnosis function Work of the lamp of "polite" illumination of the driver's door Passenger door component control module (TMB) block A67 Passenger door power window control Adjusting the position of the mirror outwardview on the passenger door Heated exterior mirrors on the passenger door Control panel and interior lighting Central locking and automatic closing Self-diagnosis function Passenger door light "polite" lighting operation Block A4 0 control airbag system (SRS) Repair manual Engine Motor endoscopy Compression measurements and analysis of results Compression metering Analysis of results Engine - removal and installation Tightening torques for screw connections Valve cover - removal and installation Intake manifold pressure chamber - removal and installation Rocker arm assembly and valve bridges - removal and installation Exhaust manifold - removal and installation Cylinder head - removal and installation Valve jumpers - adjustment Piston protrusion - measurement Measuring cylinder liner protrusion Self-locking screw connections - important information V-ribbed belts of the accessory drive and tensioners - removal and installation Generator - removal and installation Fan impeller and viscous coupling - removal and installation Crankshaft pulley - removal and installation Oil pan - removal and installation Cylinder-piston group - removal, revision of parts and installation Piston - Removal Revision of parts of the cylinder-piston group Cranks 1 Determination of the radial clearance in connecting rod bearings Connecting rod, dimensions Elbow shaft, dimensions Elbow shaft, dimensions Elbow shaft, dimensions Cylinder liner Cylinder liner - removal, replacement of seals and installation Withdrawal Replacing seals Installation Connecting Rod Piston - Installation Lubrication system - filling with oil after engine repair Starting the engine for the first time after repair Oil filter housing - removal and installation Oil-liquid heat exchanger (oil cooler) - removal and installation Oil pump - removal, inspection, repair and installation Withdrawal Checking Repair Installation Tightening torques for threaded connections Front shaft knee oil seal - replacement Engines up to and including No. 709510 Engines from 709511 and up Front cover (front oil seal housing) - removal and installation Turbocharger - removal and installation Timing case cover - removal and installation Timing case - removal and installation Withdrawal Installation Tightening torques for threaded connections Rear shaft knee oil seal - replacement Single plate clutch - removal, inspection and installation Multi-plate clutch - removal and installation Flywheel - removal, inspection and installation Exhaust Manifold Assembly with Turbocharger and Engine Brake Flap Assembly - Removing and Installing Crankshaft - removal, inspection and installation Camshaft and tappets - removal, inspection and installation Valve seals - replacement without removing the cylinder heads from the engine Valve seals - replacement (heads removed from the engine) Valves - removal and installation Valve guides - replacement "Constant choke" engine brake decompression valve - removal and installation Fuel system Fuel system - manual priming High pressure fuel pipes - replacement Tightening torques for threaded connections Return line for fuel pumps - installation Fuel Injector Assembly - Removal, Cleaning, Inspection & Installation Fuel Injector Seal Grommet - Replace High pressure fuel pumps - removal, inspection and installation Combined unit of the booster fuel pump and power steering pump - removal and installation Fuel level sensor in the tank - removal and installation Fuel tank - removal and installation Cooling system Radiator - removal and installation Fan - removal and installation Thermostat - removal and installation Tightening torques for threaded connections Water pump - removal and installation Coolant temperature sensor Exhaust system gbasics, exhaust flap engine brake and AdBlue urea solution injection system (BlueTec4 and BlueTec 5) Exhaust manifold - removal and installation Corrugated section of the exhaust system - removal and installation Connecting section of the exhaust system - removal and installation Engine brake flap assembly - removal and installation Engine brake flap assembly - repair Working pneumatic cylinder of the engine brake - removal, installation and adjustment BlueTec emission control system - description General information AdBlue tank heater Purge and depressurize individual system components Combined sensor (B117) for level and temperature of AdBlue liquid in the storage tank of the BlueTec system - removal and installation AdBlue tank - removal and installation AdBlue pump pressure tank - removal, installation and filling with compressed air Compressed air filling AdBlue fluid pressure sensor - replacement AdBlue supply line on timing case - replacement BlueTec Dispenser Supply Hose - Replace BlueTec Pump Module Inlet Filter - Replace BlueTec high pressure pipe - removal and installation BlueTec Dispenser - Removal and Installation Modified BlueTec dispenser and routing the wiring harness to its heating element BlueTec Dispenser Diffuser - Replace BlueTec Compressed Air Control Valves - Removal and Installation Solenoid (inlet) compressed air supply valve Safety (venting) air pressure limiting valve Bypass (non-return) valve Discharge line filter at the pump module of the BlueTec system - removal and installation Compressed air pressure sensor in the BlueTec system - removal and installation AdBlue liquid injection nozzle - removal and installation External pneumatic pressure reducing valve on pump module - removal and installation Bluetec ion exchanger - removal and installation Combined sensor for humidity and temperature of incoming air in the AdBlue system - removal and installation AdBlue tank heater solenoid valve - removal and installation Nitrogen oxide sensor with controller in BlueTec system - removal and installation AdBlue liquid pump module - removal and installation Withdrawal Possible replacement options during repair Pump modules with catalog number A 000 140 01 78 Pump modules with catalog numbers A 000 140 02 78 and A 000 140 03 78 Pump modules with catalog number A 000 140 04 78 Pump modules with catalog number A 000 140 05 78 Installation Electronic control unit for AdBlue system (SCR) - removal and installation Exhaust gas temperature sensors in AdBlue control system (SCR) - removal and installation Catalytic converter inlet exhaust temperature sensor Catalytic converter exhaust gas temperature sensor Engine electrical equipment Starter - removal and installation Starter - disassembly and assembly Shaft bearing in front starter housing - replacement Flywheel ring gear - replacement Generator - removal and installation Electronic voltage regulator of the generator - removal and installation Alternator pulley - replacement Generator support - removal and installation Flare preheating system for air in the pressure chamber - general information FLA system operation at outdoor air temperature below –4 ° С Flare Preheat (FLA) Components - Location and Features Clutch Coupling - removal, inspection and installation Hydraulic clutch - bleeding Processor Reprogramming Procedure (GS2 or GS7 Models) & lt; Clutch booster (models with code IY2) - removal and installation Clutch release lever (fork) - removal, check and installation Clutch Actuator (Models Code GE2, GE3 and GE7) - Removal and Installation Clutch rod travel sensor - removal and installation Clutch Master Cylinder - Replace Power take-off Power take-off - removal, inspection and installation Power take-off mechanismty - disassembly and assembly Gearbox (gearbox) Check point - removal and installation using a rolling jack through the bottom of the car Gearbox - removal and installation with a chain hoist over the top of the car Transmission Oil Temperature Sensor - Change Vehicle speed sensor - replacement Gearbox output shaft speed sensor - replacement Hydropneumatic Shift Actuator (Models GS3 and IY2) - Air Bleed Lever and gearbox hydropneumatic control unit (models with code IY2) - removal and installation Disassembly and assembly of pipe fittings of the hydropneumatic gear shift control unit Cardan drive Cardan shaft - removal and installation Propshaft suspension bearing - removal and installation Installation angles of the propeller shaft Standard mounting angles Adjusting the position of the outboard bearing Adjusting the position of the rear gear flange Rear axle Rear axle hub - removal and installation Models 749011 Models 746210/213, 748590 Rear axle wheel bearing clearance - check and adjust Checking Adjustment Rear axle assembly - removal and installation Tightening torques for threaded connections Rear axle reducer assembly (models 746210/213, 748590) - general information, removal and installation Only on rear axle models 74621 Differential blocking unit in the rear axle reducer - removing and installing Checking and adjusting the clearance in the drive of the rear axle differential lock Thru-drive reducer - removal and installation Rear axle reduction gear drive shaft oil seal - replacement Front axle Front axle (air suspension) - removal and installation Front axle (suspension with steel leaf springs) - removal and installation Front Axle Hub Assembly (Models 7339.5xx, starting from No. 179201) - Removal and Installation Front axle hub (models 739.5xx to no. 168310 - with separate tapered roller bearing) - removal and installation Front axle hub (models 73941/5 with drum brakes) - removal and installation Front Axle Hub - Bearing Replacement Front Axle Hub - Change Grease and Check Bearing Condition Non-separable front hubs models 739.5 from no. 168311 Front wheel suspension Front shock absorber - replacement Tightening torques for shock absorber nuts Front leaf springs - replacement Tightening torques for threaded connections Steering knuckle (models with disc brakes) - removal and installation Steering knuckle (models with drum brakes) - removal and installation Front Anti-roll Bar - Removing and Installing Components Front spring bushings - replacement Mandrel Kits Catalog Numbers Huck-Spin non-screw connections Front spring suspension brackets - removal and installation Tightening torques for threaded connections Rear wheel suspension Pneumatic pipe fittings - important information Design features and interchangeability The main differences between SCHAFER SDF and VOSS 232 pneumatic fittings Differences in assembly and disassembly procedures Repair and extension of plastic pneumatic pipelines of the brake system and air suspension Models with VOSS 232 or SCHAFER SDF fittings Cutting pneumatic lines Using pipe fittings Changing the Laying of Modified Piping Piping laying and fastening Permissible bending radii of pipelines Protection of pipelines from acid battery vapors Thermal protection of pipelines VOSS 230 flange connection - disassembly and assembly Disassembly Build Tightening torques for threaded connections VOSS 232 or SCHAFER SDF inlet connection Disassembly Build All models Tightening torques for threaded connections Air springs - removal and installation Air spring support - removal and installation Rear barits anti-roll bar and lateral stability - removal and installation Silent blocks of stabilizer bar - replacement Rear leaf springs - removal and installation Rear spring front support bracket - removal and installation Tightening torques for threaded connections Silent blocks of rear springs - removal and installation Rear spring rubber support - removal and installation Installation Tightening torques for threaded connections Rear suspension shock absorber - replacement Tightening torques for threaded connections Steering Steering Gears Containing Driver Airbag Assembly - Warnings Hydraulic Steering - Bleeding and Limiter Adjustment Leveling Stopper adjustment Tightening torques for threaded connections Adjusting screws on models with automatic adjustment of pressure limiters (ZF 8098) - replacement Hydraulic Limiters (Models with ZF 8098 Adjustable Pressure Limiters) - Adjustment Driver's airbag assembly - removal and installation Steering wheel - removal and installation Spiral Contact Assembly - Removal and Installation Steering column lock cylinder - removal, installation and initialization of transponder Steering column lock - removal and installation Lower steering shaft - removal and installation Post-accident steering gear - technical condition assessment Steering gear - removal and installation Pump assembly GU R / fuel pump - removal and installation Emergency pump GU R (model 765887) - removal and installation Braking system ABS sensor - removal and installation Disc brake calipers - general information Brake pads (disc brakes) - removal and installation Brake pad thickness, mm Working clearance in disc brakes - check Disc brakes - working air gap adjustment Installation Brake disc - check Brake disc dimensions, mm Brake Caliper Guides (Disc Brakes) - Check Anthers of the caliper pressure parts (disc brakes) - check Anther condition Pressing parts Disc brake working air gap adjuster - check Caliper Fixed Support Outer Plug - Replace Brake Caliper Guides - Repair Disc Brake Caliper Threaded Cylinders - Removal and Installation Clamping parts with boots (disc brakes) - removal and installation recommendations Working brake cylinder (combined, disc brakes) - modification Installation Recommendations Working brake cylinder (combined, disc brakes) - removal and installation Working brake cylinder (diaphragm, disc brakes) - removal and installation Support bracket with brake caliper - removal and installation Disc brake caliper - removal and installation Brake disc - removal and installation Working air gap in drum brakes - checking and adjusting Brake drum - removal, cleaning, inspection and installation Cleaning Checking Installation Drum brake pads - removal and installation Unbelievable bridge The working brake cylinder of the drum brake mechanism - removal and installation Brake pad wear sensor - modification, removal, inspection and installation Wear sensor modification Withdrawal Checking Installation Automatic regulator of the working air gap in the drive of the drum brake mechanism - removal, installation and adjustment Withdrawal Installation Adjustment Camshaft and drum brake drive support bracket - removal and installation Drum brake support - removal and installation List of abbreviations used Russians Latin Wiring diagrams

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