Mercedes Actros III 2008 thru 2011, repair 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

Customers reviews