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  Towing — Recovery Atego…
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  Service Towing – Recovery Atego Guidelines for Breakdown Services 2009 Edition Daimler AG · Teile-Technik und Technische Information (GSP/TID) · D-70546 Stuttgart…
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  Information and copyright If you have any questions or problems in connection with the towing or recovery of Atego vehicles, please contact: Daimler AG Technical Field Service Tel. +49 711/17 – 59 762 Technical details of the data and illustrations provided in these guidelines are subject to change without notice.

• Page 5: Table Of Contents

  Contents General Safety and liability information Conventions Vehicle identification Description and roadside assistance Quick guide Instrument panel Overview Standard onboard computer Plus onboard computer Display messages STOP lamp Symbol and text messages System abbreviations Indicator lamps Warning buzzer Oil level in engine Oil level in automatic transmission Fuel system Overview of fuel system…

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  Contents Transmission Manual gearshift system Automatic transmission ® Telligent automatic gearshift system ® Teach-in process (vehicles with Telligent automatic gearshift system) Teach-in errors Emergency shift (live PTO) Brake system General Frequent-stop brake Hill holder Overview of compressed air reservoirs Filling the compressed air system from an external source Releasing the spring-loaded parking brake ®…
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  Contents Recovery Recovery General Maximum permissible pulling forces Safety components Special tools Special tools Guidelines for Breakdown Services (Subject to technical modifications)

• Page 8: Safety And Liability Information

  Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

• Page 9: Vehicle Identification

  Vehicle identification Vehicle model designation 12 24 Permissible gross vehicle weight in tonnes 24 Engine output in hp (x 10) Location of vehicle model plate/vehicle identification number Model plate (example) Vehicle identification number on right longitudinal frame member Vehicle identification number (example) Guidelines for Breakdown Services (Subject to technical modifications)

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  Vehicle identification Data on the vehicle model plate • Vehicle model • Headlamp basic setting • Smoke index • Rear axle ratio • Vehicle identification number (VIN) • Permissible gross vehicle weight • Permissible axle loads (example) Key to vehicle identification number Vehicle identification number (VIN) 970.213 1 K 896063…

• Page 11: Quick Guide

  Quick guide Instrument panel Overview………………….Page 11 Reservoir pressure gauge for brake circuit 1 or 2……….Page 12 Gear indicator ………………..Page 13 ® Fuel/AdBlue level gauge …………….Page 14 Standard onboard computer…………….Page 16 Plus onboard computer………………Page 20 Display messages ………………..

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  Quick guide Transmission Overview of transmissions…………….Page 68 Manual gearshift system……………… Page 69 Automatic transmission ………………. Page 71 ® Telligent automatic gearshift system…………. Page 73 ® Teach-in process for Telligent automatic gearshift system……Page 75 Teach-in errors………………..Page 77 Emergency shift of power take-off (live PTO) ……….. Page 78 Brake system General ………………….

• Page 13: Instrument Panel

  Instrument panel Overview Standard Plus onboard onboard computer computer The Standard and Plus onboard computers can be distinguished by the symbols on the control pad. Vehicles with Plus onboard computer have an additional display in the tachometer (outside/coolant temperature display 3) and a display in the speedometer (total mileage 4). ®…

• Page 14: Reservoir Pressure Gauge For Brake Circuit 1 Or 2

  Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

• Page 15: Gear Indicator

  Instrument panel Gear indicator Telligent ® automatic gearshift system Ì Standard onboard computer Í Plus onboard computer Engaged: 4th gear Recommended or preselected: 3rd gear The display shows the engaged gear 1 and the recommended or preselected gear 2. 1st to 6th gear Transmission neutral Reverse gear Guidelines for Breakdown Services (Subject to technical modifications)

• Page 16: Fuel/Adblue ® Level Gauge

  Instrument panel ® Fuel/AdBlue level gauge ® AdBlue level gauge Fuel level gauge Turn vehicle key in steering lock to drive position. ® Check level on fuel/AdBlue level gauge and top up if necessary. Switch off the engine and the auxiliary heater be- fore filling the reservoir.

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  Instrument panel ® AdBlue supply exhausted ® If the AdBlue supply is exhausted or there is a Segments All segments are off malfunction, the engine power may be signifi- Display Standard onboard computer: cantly reduced the first time the vehicle comes to a standstill.

• Page 18: Standard Onboard Computer

  Instrument panel Standard onboard computer Design and operation The Standard onboard computer is activated as soon as you turn the vehicle key in the steering lock to the drive position. The Standard onboard computer allows you to call up information about your vehicle and to make and change various settings.

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  Instrument panel Default display Outside/coolant temperature display Main odometer Trip odometer Time The TRIP button can be used to change between the trip mileage display and the trip data in the instrument panel. If the Standard onboard computer detects malfunctions in the system, the messages appear in sequence on the display and the segments of the status indicator lights up yellow or red, see page 27.
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  Instrument panel Menus in detail The number and sequence of the menus depend on the vehicle model and the vehicle equipment. The values given are examples. Risk of accident Operating the onboard computer while driving can distract your attention away from what is happening on the road.
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  Instrument panel Menu structure Description Total axle load: Axle load: … other axle The front axle (VA/FA) or loads: rear axle (HA/RA) GES 23.5t VA 7.5t indicated flashes in the SUM 23.5t FA 7.5t Axle load HA 1 display. RA 1 The axle load display is not Axle load HA 2…

• Page 22: Plus Onboard Computer

  Instrument panel Plus onboard computer Design and operation The Plus onboard computer is activated as soon as you turn the vehicle key in the steering lock to the drive position. The Plus onboard computer allows you to call up information about your vehicle and to make and change various settings.

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  Instrument panel If the Plus onboard computer detects malfunctions in the system, the display messages appear in sequence and the segments of the status indicator lights up yellow or red, see page 27. Confirming display messages, see page 27. Display fields The display fields are actuated according to the installed equipment or the activated functions.
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  Instrument panel Menus in detail The number and sequence of the menus depend on the vehicle model and the vehicle equipment. The values given are examples. Risk of accident Operating the onboard computer while driving can distract your attention away from what is happening on the road.
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  Instrument panel Home menu The home menu follows a circular pattern and contains the following displays, depending on the vehicle equipment: • Default display with speed • Date display • Info display • Trip computer • Radio • Navigation ‚ ƒ…
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  Instrument panel Default display Speed display Time Trip mileage Main menus and submenus The various main menus each comprise a number of functions pertaining to the same subject. In the Check Info main menu, the submenus Reservoir pressure Oil level Axle load indicator etc.
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  Instrument panel menu Check Info „ º ‚ ƒ „ ‚ Call up home menu ( ), Check Info main menu ( ), and submenu ( ƒ). Description » „ AdBlue tank AdBlue The tank content is tank 28 l displayed as a bar graph.
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  Instrument panel menu Service Info „ º ‚ ƒ „ Call up main menu ( ) and Service Info main menu ( Description RESET condensation? submenu only appears in conjunction with a relevant RESET condensation? display message, see page 27. In some cases the condensation message can be reset by pressing the Reset button.

• Page 29: Display Messages

  Instrument panel Display messages Display messages are operating information, fault messages or warnings that appear automatically in the display. The segments of the status indicator light up yellow or red depending on the priority rating. In addition to the display message, an indicator lamp in the instrument panel may light up. Display messages can be canceled and called up at a later time.

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  Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

• Page 31: Stop Lamp

  Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

• Page 32: Symbol And Text Messages

  Instrument panel Symbol and text messages Display message with yellow status indicator Standard Plus onboard Possible cause/consequence Possible remedy onboard computer: computer: Ã ~Ã Switch on antilock brake system Risk of accident (ABS). Malfunction in brake system of Malfunction If the fault is still displayed: vehicle (indicator lamp in trailer lights up) and/or of trailer/…

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  The condensation level in the Have the following work carried out compressed air reservoirs is too without delay at a qualified specialist Condensation high. workshop, e.g. a Mercedes-Benz in compressed service center. air reservoir Even at temperatures around freezing (0 °C), condensation in Drain condensation from com- pressed air reservoir.
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  Instrument panel Display message with yellow status indicator Standard Plus onboard Possible cause/consequence Possible remedy onboard computer: computer: ¥ ¥. Stop the vehicle as soon as possible Risk of accident taking into account the traffic situa- The reservoir pressure in the tion.
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  The engine output is reduced. If the engine is still running in limp- home mode: Have the fault rectified at a qualified specialist workshop, e.g. a Mercedes-Benz service cen- ter. The automatic transmission has Continue driving with special care. shifting problems.
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  Instrument panel Display message with yellow status indicator Standard Plus onboard Possible cause/consequence Possible remedy onboard computer: computer: ÕÃ The cargo fluid level set on the Have the cargo monitor checked at a qualified workshop. cargo monitor in the trailer/ Cargo fluid semitrailer has been exceeded (example)
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  Instrument panel Display message with yellow status indicator Standard Plus onboard Possible cause/consequence Possible remedy onboard computer: computer: • When the lights are switched Check and replace the appropriate fuses. Bulb/fuse Check the appropriate bulb and re- Bulb or fuse for standing defective place if necessary.

• Page 38: Display Messages With Red Status Indicator

  Instrument panel Display message with red status indicator Standard Plus onboard Possible cause/consequence Possible remedy onboard computer: computer: N Ã ~Ã Risk of accident Drive with special care. Avoid heavy braking, except in emergency situa- The antilock brake system Malfunction tions, so that the wheels of the trail- (ABS) in the trailer/semitrailer in trailer…

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  Instrument panel Display message with red status indicator Standard Plus onboard Possible cause/consequence Possible remedy onboard computer: computer: ® ® «. The AdBlue supply is Fill AdBlue tank. 0% 0 l exhausted. The indicator lamp ® When the AdBlue supply is topped up, Power reduced ±…
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  The air filter is clogged. Have the air filter replaced at a qual- ified specialist workshop at the first The engine output may be Air filter opportunity, e.g. at a Mercedes-Benz reduced. clogged service center. Service due i The display message consists of 2 parts.
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  Instrument panel Display message with red status indicator Standard Plus onboard Possible cause/consequence Possible remedy onboard computer: computer: ¬ ¬. The engine oil level is too high. Have at least 2 liters of engine oil drained or extracted at a qualified This can cause the engine oil Drain the workshop.
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  Instrument panel Display message with red status indicator Standard Plus onboard Possible cause/consequence Possible remedy onboard computer: computer: The coolant level has dropped 2 Stop the vehicle as soon as possible taking into account the traffic situa- liters below the normal fill level. Top up tion.
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  Instrument panel Display message with red status indicator Standard Plus onboard Possible cause/consequence Possible remedy onboard computer: computer: £ £. Have the brake system checked at a Risk of accident qualified workshop. Malfunction in brake system of The braking vehicle (indicator lamp behavior may lights up).

• Page 44: System Abbreviations

  Instrument panel System abbreviations Abbrevia- System Abbrevia- System tion tion Antilock brake system Comfort locking system ® Automatic transmission Telligent engine control ® ® Telligent brake system Telligent level control Electronic trailer brake Parameterizable special module Radio remote control Retarder control Cold-start aid Supplemental restraint system Drive control…

• Page 45: Indicator Lamps

  Instrument panel Indicator lamps Indicator lamp Function & Turn signal indicator, tractor vehicle, left Turn signal indicator, tractor vehicle, right High beam Permanent brake Parking brake STOP lamp (see page 29) Ÿ Cab lock (see page 91) Acceleration skid control (ASR) Apply brake —…

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  Always have service work performed at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. In particular, it is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.
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  Always have service work performed at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. In particular, it is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

• Page 48: Warning Buzzer

  Warning buzzer Warning buzzer The warning buzzer sounds in addition to the operating information in the display. Warning buzzer function (test circuit) Turn vehicle key in steering lock to drive position. The warning buzzer sounds for about 2 seconds. Overview of warning buzzer in addition to display message or indicator lamp ª…

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  Warning buzzer ª Warning buzzer sounds when Display Action Display failure. Tow the vehicle away. Important operating information, warnings or service indicators in the display can no longer be shown. With lights switched on and the vehicle Switch off lights. key removed.

• Page 50: Oil Level In Engine

  Oil level in engine Calling up the engine oil level in the display (Standard onboard computer) To check the engine oil level the vehicle must be parked on level ground and the engine must be at operating temperature and must have been switched off for at least one minute. If the engine oil level is called up earlier, the display will not show the correct quantity.

• Page 51: Topping Up The Engine Oil

  Oil level in engine Topping up engine oil The filler neck for the engine oil is at the front of the vehicle behind the maintenance flap. If the oil level in the engine is too low or too high, the status indicator lights up yellow and the display shows and the necessary top-up quantity, or…

• Page 52: Oil Level In Automatic Transmission

  Oil level in automatic transmission Oil level in automatic transmission To check the oil level in the automatic transmission the vehicle must be parked on level ground and the transmission must be at operating temperature. If the indicator lamp lights up or flashes while driving, the temperature of the transmission oil or coolant is too high.

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  Oil level in automatic transmission Fault code display during transmission oil level measurement Code Cause Remedy oL 50 Engine speed too low. Make sure engine is at idle speed. oL 59 Engine speed too high. Make sure engine is at idle speed. oL 65 Transmission is not in neutral N.
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  Oil level in automatic transmission Checking the transmission oil level using the oil dipstick Oil dipstick Oil filler neck Warm zone Cold zone Checking the transmission oil level Park the vehicle on a flat, horizontal surface. Apply parking brake. Shift transmission to neutral N. Start engine and run at idle speed for about 1 minute.

• Page 55: Fuel System

  Fuel system Fuel system overview (example) ® AdBlue tank Fuel filter Fuel tank with fuel pump unit High pressure pumps Hand pump (example) Fuel pump Location of hand pump, (see page 56). Injection nozzles Engine control unit Guidelines for Breakdown Services (Subject to technical modifications)

• Page 56: Fuel System/Adblue

  Fuel system Fuel tank Main fuel tank The main fuel tank is usually located on the right- hand side of the vehicle frame. The main fuel tank can be recognized by the fuel pump unit. Additional fuel tank Additional fuel tanks may be mounted on the left or right side of the vehicle frame and are identifiable by a cap with vent line or by a fuel pump unit with no electrical connection.

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  Fuel system Combination tank Filler neck Diesel fuel Hydraulic fluid The combination tank consists of two separate chambers for diesel fuel and hydraulic fluid. It is possible for the hydraulic tank to be installed separately. AdBlue ® tank ® The AdBlue tank is located on the right-hand side of the vehicle frame and is identifiable by its blue cap.

• Page 58: Hand Pump (Location)

  Fuel system Hand pump (location) A hand pump is integrated into the top section of the fuel prefilter housing. The fuel prefilter may be installed in various locations depending on the vehicle version. Hand pump Shutoff valve Sightglass Drain screw Fuel prefilter with hand pump on cab rear panel Fuel prefilter with hand pump on frame Guidelines for Breakdown Services (Subject to technical modifications)

• Page 59: Checking The Fuel System

  Fuel system Checking the fuel system Check that the sightglass 1 of the fuel prefilter is full of diesel fuel. If the sightglass 1 is not full of diesel: Bleed/de- water the fuel system, see page 58. When driving uphill/downhill with an almost empty fuel tank, the system may be unable to draw fuel from the tank.

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  Fuel system Bleeding Press hand pump 3 of fuel prefilter repeatedly until the filter housing is completely filled with fuel. Start engine and run for about 1 minute. The fuel system bleeds itself automatically. Environmental warning Dispose of the water/fuel mixture properly without contaminating the environment. Vehicles with fuel prefilter and heated water separator Dewatering Before bleeding, check whether water has settled in the sightglass 1.

• Page 61: Electrical System

  Electrical system Overview of electrical system EMERGENCY OFF switch on carrier frame EMERGENCY OFF switch on dashboard (see page 60) (see page 60) Batteries (see page 62) Guidelines for Breakdown Services (Subject to technical modifications)

• Page 62: Emergency Off Switch

  Electrical system EMERGENCY OFF switch Vehicles used to transport hazardous goods are equipped with two EMERGENCY OFF switches. The switches are used to interrupt the power supply in an emergency. This prevents short circuits with sparks which may ignite a fire or an explosion. Risk of accident Press the EMERGENCY OFF switch only in the event of danger and only when the vehicle is stationary;…

• Page 63: Jump Starting

  Electrical system Jump starting When the vehicle batteries are flat, another vehicle can be used to jump start the engine. Risk of explosion While jump starting, deflagration may occur due to gases escaping from the batteries. Avoid producing sparks. Do not use open flames near batteries, and do not smoke. When handling batteries, always comply with the safety information and precautions, see page 62 Before jump starting, the condition of the batteries must be checked.

• Page 64: Batteries

  Dispose of batteries in an environmentally acceptable way. Hand in batteries to a specialist workshop, e.g. a Mercedes-Benz service center, or a recycling station for used batteries. Full batteries must be transported and stored upright. Secure batteries to prevent them from tipping over while transporting.

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  Electrical system Disconnecting and connecting batteries The batteries are on the left-hand side on the frame behind the cab. Risk of injury There is a risk of short circuit if the positive terminal of the connected battery comes into contact with vehicle parts.

• Page 66: Fuses

  Electrical system Fuses Risk of fire Do not use fuses with a higher amperage than that specified. This could result in damage to the electrical system and even cable fires. Only use fuses of the specified amperage and never bridge or repair any fuses. Only replace fuses when the cause of the fault has been rectified.

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  Electrical system Location of fuses in main fuse carrier Spare fuses Fuses F1 – F41 Relays Fuse assignment of Atego base module Consumer Consumer Fog lamps, including trailer 10 A Headlamp cleaning system 10 A Instrument/switch illumination, 10 A Alternator, transmission, heavy vehicle…
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  Electrical system Consumer Consumer Left taillight, standing light, side 10 A Trailer socket ABS, condensation 10 A marker lamp, trailer socket, Toll sensor Collect terminal 58 Right taillight, standing light, side 10 A Not assigned marker lamp, trailer socket Transmission control 10 A Windshield washer system 10 A…
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  Electrical system Fuse assignment of Atego additional fuse carrier Fuse module A1 Consumer Consumer Auxiliary heater clock, Toll Collect, 10 A Central locking/comfort locking 10 A ® FleetBoard terminal 30 system, radio remote control Auxiliary heater 20 A Compressed air drier…

• Page 70: Transmission

  Transmission Overview of transmissions The Atego is available with three different versions of transmission shift. Manual gearshift system, see page 69 Automatic transmission, see page 71 ® Telligent automatic gearshift system, see page 73 Guidelines for Breakdown Services (Subject to technical modifications)

• Page 71: Manual Gearshift System

  Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

• Page 72
  Have the malfunction repaired immediately at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work.

• Page 73: Automatic Transmission

  Transmission Automatic transmission Risk of accident Do not shift down to braking on slippery roads. The drive wheels could lose grip and the vehicle could start to skid. The automatic transmission is equipped with a button shift. The individual gears are shifted automatically according to: •…

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  Transmission Starting off Apply the service brake; do not depress the accelerator pedal. Press button D 6 or R 8. Vehicles with backup warning system: The backup warning system sounds in reverse gear. Only release the brakes when ready to move off, otherwise there is a risk of the vehicle starting off prema- turely (creeping forward).

• Page 75: Telligent ® Automatic Gearshift System

  Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

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  Transmission Operating modes Automatic mode Press mode selector switch 5. Vehicles with Standard onboard computer: The display shows constantly. Vehicles with Plus onboard computer: The display shows Auto constantly. Manual mode Press mode selector switch 5. Vehicles with Standard onboard computer: The display shows constantly.

• Page 77: Teach-In Process (Vehicles With Telligent ® Automatic Gearshift System)

  Transmission Teach-in process The teach-in process cannot be performed in vehicles with automatic transmission. ® In vehicles with Telligent automatic gearshift system, the minor or major teach-in process is necessary in order to program vehicle-specific data in the electronic system of the transmission control (GS), e.g. if the clutch has been replaced or a fault has occurred.

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  If the fault displays do not disappear after the teach-in process, have the fault rectified at a qualified specialist workshop possessing the required expertise and tools in order to perform the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. Guidelines for Breakdown Services (Subject to technical modifications)

• Page 79: Teach-In Errors

  Mercedes-Benz recommends a Mercedes-Benz service center for this work. GS 19 Vehicle rolling. Apply parking brake. GS 20 The display shows U <<<…

• Page 80: Emergency Shift (Live Pto)

  Brake system General In the basic version the service brake is a pneumatically controlled brake with antilock brake system (ABS). As ® ® well as the basic version, the service brake is also available as the Telligent brake system. The Telligent brake system features an electronic control system to control and monitor the brake system and incorporating the following systems:…

• Page 81: Frequent-Stop Brake

  Brake system Frequent-stop brake The frequent-stop brake requires less compressed air than the parking brake. When the frequent-stop brake switch is operated, a certain brake pressure is applied to all brake cylinders. The parking brake system is unaffected. Risk of accident The parking brake must be applied in order to switch off the engine.

• Page 82: Hill Holder

  Brake system Hill holder ® The hill holder is part of the Telligent brake system and assists with moving off on gradients. When the hill holder is switched on, it remains in the ready state in forward and reverse gear even after an intermediate stop or when the engine is switched off.

• Page 83: Overview Of Compressed Air Reservoirs

  Brake system Overview of compressed air reservoirs Compressed air reservoir, circuit 1 Separate compressed air reservoir Compressed air reservoir, circuit 2 Compressed air drier Compressed air reservoir, circuit 4 Four-circuit protection valve Compressed air reservoir, circuit 3 Filling the compressed air system from an external source The entire compressed-air system can only be filled from an external source via the tire inflation connection 1 or via the coupling head/filler connection (see page 90).

• Page 84: Releasing The Spring-Loaded Parking Brake

  Brake system The tire inflation connection 1 is located on the compressed air drier. If the compressed air system is filled via the tire inflation connection 1, the compressed air is neither cleaned nor dried. The pressure safeguard of the pressure regulator is bypassed.

• Page 85: Releasing Mechanically

  Brake system Releasing the spring-loaded parking brake mechanically In an emergency, if there is insufficient reservoir pressure in the brake system, the spring-loaded parking brake can be released mechanically to allow the vehicle to be towed away. Risk of accident Before releasing the spring-loaded parking brake, secure the vehicle with wheel chocks to prevent it from rolling.

• Page 86
  Brake system Cotter pin Stop plug Release bolt Bracket (for release bolt) Washer Releasing the spring-loaded parking brake mechanically Remove cotter pin 1 and unscrew nut 2. Remove washer 6. Pull release bolt 4 out of bracket 5. Remove stop plug 3. Insert release bolt 4 into hole of spring-loaded cylinder and turn 90°…
• Page 87
  Brake system Restoring spring-loaded parking brake to driving position Clean and grease release screws before screwing in. Fill brake system up to cutoff pressure. Move lever of parking brake valve to release position. Unscrew nut 2 with washer 6 from release bolt 4. Unscrewing the nut 2 retightens the spring in the spring-loaded cylinder.

• Page 88: Telligent® Level Control

  Telligent® level control Diagram of Telligent level control ® ® Telligent level control operating unit (beside Air spring bellows with test valve (2-bellows driver seat) system) Compressed air reservoir Valve block for front or rear axle Air spring bellows (4-bellows system) Filler and test connections for air suspension system Because of the pneumatic pilot control, a reservoir pressure is always necessary to actuate the air…

• Page 89: General

  Telligent® level control General The chassis frame can be raised/lowered. Vehicles with air-sprung rear axle: The chassis frame can only be raised or lowered at the rear axle. Vehicles with full air suspension: The chassis frame can be raised or lowered at the front and rear axles. When the vehicle key in the ignition lock is in the drive position, the height of the chassis frame readjusts automatically.

• Page 90: Raising/Lowering The Chassis Frame

  Telligent® level control Raising/lowering the chassis frame Risk of accident When driving with a raised driving level, there is a risk of damage if you fail to observe the headroom of underpasses. Do not exceed the maximum permissible vehicle height when driving with a raised driving level. In the Federal Republic of Germany the permissible vehicle height is limited to 4 m.

• Page 91
  Telligent® level control Normal level When continuing to drive after changing the chassis frame height, you must return the chassis frame to the normal level (driving position). Press normal level button 7. The operation indicator lamps go out. The chassis frame rises or drops to the stored height automatically. When the normal level (driving position) is reached, the display in the display and the status indicator go out.

• Page 92: Filling The Air Suspension System From An External Source

  Telligent® level control Filling the air suspension system from an external source If it is not possible to fill the air suspension system via the tire inflation connection 1 or the coupling head 2 (see page 81), the system can be filled directly via the test connection 5.

• Page 93: Tilting The Cab

  Tilting the cab Tilting the cab Before tilting the cab Apply parking brake. Shift transmission to neutral. Switch off engine. Switch off auxiliary heater. If you have to start the engine after tilting the cab: Turn the vehicle key in the steering lock to the drive po- sition.

• Page 94
  Tilting the cab Tilting the cab forward Unlock the cab lock using the operating lever 1 on the right behind the passenger seat. Unlock safety catch 2 using operating lever. Unlocking can be facilitated by pulling the cab downwards by the grab handles. Tilt cab forward by the grab handles.

• Page 95: Mechanical/Hydraulic

  If the tilting hydraulics are defective or leaking, contact a qualified specialist workshop possessing the required expertise and tools for the necessary work. Mercedes-Benz recommends a Mercedes-Benz service center for this work. It is absolutely essential that all safety-relevant work and all work on safety-relevant systems is performed by a qualified specialist workshop.

• Page 96
  Tilting the cab Tilting back to driving position Risk of accident Before driving off, make sure that the valve lever is at «Lower to driving position». Otherwise there is a danger that the cab lock could open by itself while driving and the cab could tip forward if the vehicle brakes hard.

• Page 97: Engine

  Engine Starting and stopping the engine with the cab tilted Risk of injury When the cab is tilted and the engine is running, make sure that you do not touch hot or moving engine parts (e.g. exhaust manifold, poly-V belt, fan). You may be injured. If working on public roads, pay attention to the traffic situation and secure the area around the vehicle accordingly.

• Page 98
  Engine Vehicles with one pushbutton on the engine The pushbutton is on the left-hand side of the engine. Starting the engine Hold down the start/stop pushbutton 1 until the engine starts. If a gear is engaged, the start/stop pushbutton 1 is inoperative.

• Page 99: Tow-Starting

  Tow-starting General Risk of accident • If the reservoir pressure in the compressed air system is too low or nonexistent (STOP lamp lights up below 6.8 bar), there will not be adequate braking effect. The clutch booster and gearshift system may be inoperative depending on the pressure level.

• Page 100: Tow-Starting Vehicles With Manual Gearshift System

  Tow-starting Swing cover of coupling jaw down. Disengage coupling pin 1, swing forward about 90° and pull out upwards. Insert tow bar into coupling jaw. Engage coupling pin 1 in the catch with an audi- ble click. Tow-starting vehicles with manual transmission Fully depress clutch pedal.

• Page 101: Vehicles With Telligent ® Automatic Gearshift System

  Tow-starting ® Vehicles with Telligent automatic gearshift system Shift to 2nd gear. The engaged gear must be shown in the display. Tow-start vehicle. At about 20 km/h slowly depress accelerator pedal. The electronic system engages the clutch automatically. Immediately after the engine starts: Shift transmission to neutral.

• Page 102: Quick Guide

  Quick guide General Hazard information ………………Page 101 General rules for towing ……………… Page 102 Propeller shaft removal………………Page 102 Electrical circuits Deactivating acceleration skid control (ASR) ……….. Page 103 Switching transfer case to road position …………Page 103 Air brake system Maintenance flap/cover ………………

• Page 103: Towing

  Towing General Hazard information Risk of accident If the vehicle must be transported on a low loader (e.g. after an accident), the maximum permissible vehicle height may be exceeded. Drive with particular care and attention. Observe the maximum headroom of bridges and underpasses.

• Page 104: General Rules For Towing

  Towing General rules for towing • The propeller shafts must be removed to avoid damage to the transmission and transfer case, see page 102. • The safety features for ASR must be switched off, see page 103. • The transfer case must be switched to road position, see page 103. •…

• Page 105: Electrical Circuits

  Towing Electrical circuits Deactivating acceleration skid control (ASR) Deactivating acceleration skid control (ASR): Turn vehicle key in steering lock to drive position. Press top of ASR shutoff switch. The indicator lamp in the instrument panel flashes. The ASR system is reactivated automatically when the engine is switched off and restarted.

• Page 106: Air Brake System

  Towing Air brake system If the engine of the vehicle to be towed is inoperative, a compressed air connection must be made from the towing vehicle to the towed vehicle in order to guarantee a constant reservoir pressure in the compressed air system.

• Page 107: Connecting An External Compressed Air Source

  Towing Connecting an external source Open maintenance flap. Unscrew cover, see page 104. Different service brake valves may be installed depending on the vehicle version. On vehicles raised at the front for towing: Un- screw connection 21 1 on service brake valve. On vehicles raised at the rear for towing: Un- screw connection 22 2 on service brake valve.

• Page 108
  Towing Connect compressed air supply line of towing ve- hicle (red coupling head) to tire inflation connection 3 or to front coupling head. A reservoir pressure of 10 bar is required. When filling directly at four-circuit protection valve: Test connection 22 for rear axle brake circuit, test connection 21 for front axle brake circuit.

• Page 109: Stopped Engine, Transmission And/Or Axle Damage

  Towing Notes on stopped engine, transmission and/or axle damage Stopped engine Comply with section entitled «Towing with a tow bar», see page 111. Remove propeller shaft to drive axles complete. If it is not possible to remove the propeller shaft, remove the appropriate drive shafts, see page 109. All-wheel drive vehicles: Switch transfer case to road position.

• Page 110: Drive Shafts

  Towing Drive shafts Ascertaining the damage location on a blocked drive train Secure the vehicle to prevent it from rolling. Start engine. Fill compressed air system up to cutoff pressure. Release parking brake. The indicator lamp and the STOP lamp in the instrument panel must not light up. Disengage the clutch, select a gear and gradually release the clutch pedal.

• Page 111: Removing The Rear Axle Drive Shafts

  Towing Removing the rear axle drive shafts Engaging differential lock with bolt (HL4): Remove cable connector 1 from shift cylinder housing 2. Unscrew switch using socket wrench (size 24 mm). Carefully screw bolt 3 all the way into shift cyl- inder housing 2.

• Page 112
  Towing Removing drive shafts on rear axles HL 2 and HL 4: Turn the vehicle key in the steering lock all the way back or remove. Engage differential lock (interwheel differential lock) with bolt. Unscrew bolts 1 on wheel hubs. Place oil pan under wheel hub.

• Page 113: Preparations For Towing

  Towing Preparations for towing Towing with a tow bar Do not tow the vehicle without a compressed air supply. Always use a tow bar for towing. If possible, tow the vehicle empty; unload the vehicle if necessary in order to avoid consequential damage.

• Page 114: Overview Of Towing Options

  Towing Vehicles involved in an accident: Before raising the vehicle, check the connections between the frame sections and between the frame and the axle. On air-sprung vehicles: Set air suspension (on the raised axle) to «Lower». If the air spring bellows on a rolling axle are defective, ensure adequate clearance and tow at a maximum of 10 km/h.

• Page 115: Raising By The Wheels

  Towing Raising by the wheels (taking the Actros as an example) Secure vehicle using wheel chocks to prevent it from rolling. Set the lift fork 2 to the track width of the vehi- cle. Raise the vehicle with the aid of inflatable jacks if necessary.

• Page 116: Raising By The Front Axle

  Towing Raising by the front axle Lift the front axle with lifting forks 1. Ensure that the steering linkage, springs, stabilizer bars, hos- es and cables are not damaged. Secure the front axle to the lifting device with chains 2. Air-sprung vehicles Do not raise the vehicle by the front crossmember.

• Page 117: Raising By The Leaf Springs (Construction Site Vehicles Only)

  Towing Raising by the leaf springs (construction site vehicles only) In certain vehicles a crossmember may be installed under the spring mounting. The spring support 1 cannot be used on these vehicles. Only unladen vehicles should be raised by the leaf springs.

• Page 118: Raising At The Rear

  Towing Raising at the rear On vehicles with driven front axle: Remove pro- peller shaft between transfer case and front axle complete; mark the propeller shaft before remov- ing. Remove the vehicle key from the steering lock and engage the steering wheel lock. Secure the steering wheel with two additional straps 1 in the tangential direction to prevent it from turning.

• Page 119: Raising The Vehicle At The Rear Crossmember

  Towing Tie the axle up to the frame with chains. Place a wooden block between the frame and the chain. Attach lifting device. Secure the vehicle to the lifting device with straps. Observe the tire pressure and changes in the tire temperature. The front axle load increases when multi-axle vehicles are raised at the last axle.

• Page 120
  Recovery General The force application points referred to in these guidelines do not have an infinite load capacity. They should only be regarded as suitable points for the application of external forces and are intended for experienced recovery experts. Application of these instructions is left to the discretion of the recovery experts. The steering may be damaged if the vehicle is towed with recovery tools which are fastened to the wheels/ hubs on steering axles.
• Page 121
  Recovery Maximum permissible pulling forces Recovery at the front coupling jaw • Atego up to 12t with 17.5“ tires Permissible pulling force: 6t • Atego over 12t with 19.5“ tires Permissible pulling force: 8t Recovering by the axle (sunken vehicles) Attach towing straps to axle housing.
• Page 122
  Recovery Safety components When recovering a vehicle, pay attention to the following safety components: Frame • Longitudinal members and crossmembers. • Cab mounting including catch. Steering system • Steering shaft, steering wheel with steering lock, steering gear, steering gear pitman arms, pitman arms, steering cylinders, drag links, track levers, tie rods and joints.
• Page 123
  Special tools Mercedes-Benz special tools The following special tools/aids can be acquired from any Mercedes-Benz service center. Special tools and bolts are not included in the vehicle tool kit. Bolt M 18 x 1.5 x 60 mm (for locking the rear axle differentials, see page 109).
• Page 124
  Special tools Compressed air hose Connection Hose Adapter Coupling head Lifting fork Front axle lifting fork Spacer plate Guidelines for Breakdown Services (Subject to technical modifications)
• Page 125
  Special tools Shop-made special tools Square wooden block for rear crossmember Wheel hub cover HL4 Item Designation Dimension Diameter 190 mm Hole circle radius 78 mm Hole diameter 17 mm Wheel hub cover HL2 Item Designation Dimension Diameter 194 mm Hole circle radius, outside 82 mm Hole circle radius, inside…
• Page 126
  Special tools The following special tools/aids are recommended by Mercedes-Benz Inflatable jack Lift height up to 200 mm, lift force up to 9000 kg Guidelines for Breakdown Services (Subject to technical modifications)
• Page 127
  Index Abbreviation Electrical system ABS 42 Mechanical/hydraulic EMERGENCY OFF switch AGN 42 cab tilt system 93 Emergency release connection BS 42 Starting and stopping the engine Emergency shift, live PTO EAB 42 with the cab tilted 95 Engine diagnosis indicator lamp EDW 42 Tilting 91 FLA 42…
• Page 128
  Index Gear indicator Maintenance flap Quick charger ® Telligent automatic gearshift Manual gearshift system Quick guide system 13 6-speed transmission 70 Description and roadside Ground cable 9-speed transmission 70 assistance 9 Towing 100 Guide pulleys Manual transmission Guidelines Maximum filling pressure Trade association 6 Menu overview of Plus onboard Rear axle damage…
• Page 129
  Index Teach-in errors Valve block ® Telligent Vehicle automatic gearshift Identification number 8 system Model designation 7 Automatic mode 74 Raising at the frame 114 General 73 Raising at the rear Manual mode 74 crossmember 117 Shift control unit 73 Raising by the leaf springs 115 ®…
• Page 131
  Daimler AG, GSP/OI, HPC R 822, D-70546 Stuttgart Technical status 10/2008…

Dear Reader,

This Introduction into Service Manual presents the new Atego (model 967).

This brochure is intended for the use of technical personnel familiar with the service and maintenance of Mercedes-Benz trucks. It is assumed here that the reader is already familiar with the Mercedes-Benz model series currently on the market.

In terms of the contents, the emphasis in this Introduction into Service Manual is on presenting new and modified components and systems.

All of the data in this brochure correspond to the technical status as of the copy deadline in February 2013 and may therefore differ from the current production configuration.

We will publish modifications and new features in the relevant WIS documents only. Individual details in this brochure may therefore differ from more up-to-date versions published in WIS.

Daimler AG

Wörth plant (GSP/TTH)

February 2013

BBNote

All of the displays and messages of the multifunction display are shown in German because the corresponding versions in other languages were not available at the copy deadline.

BBNote

Information about the vehicles and about operating the vehicle functions can also be found in the interactive owner‘s manual on the Internet.

This Introduction into Service manual is also available in digital form as a PDF in SDmedia.

New features/modifications

New features/modifications

Innovations

•New engines OM 934 (4-cylinder) and OM 936 (6-cylin- der) as standard with Euro VI in seven output stages from 115 to 220 kW

•Nine different transmissions that are optimized for the intended application

•Shift-by-wire with power-assisted gear shifting

•Automated gearshift, Mercedes PowerShift 3 with the transmission functions crawling mode and EcoRoll, and transmission modes that can be individually selected

•Permanent magnet retarder

•New model designation (967.603) for fire-fighting vehicles 9.8 t, steel suspension, in two wheelbases

W46.10-1040-00

• Separate model designation for municipal vehicles (use of Multifunction steering wheel sweeper body)

•Short/extended/long cab and crew cabin, available in two roof variants ClassicSpace and BigSpace

•New 4-point cab suspension (mechanical/hydraulic)

•Electronic air-processing unit as on Actros/Antos/Arocs

•Driver seat and front passenger seat with armrests (SA), with flat-weave fabric (standard) and in velour (SA)

•Electronic Stability Program (ESP®) as standard (not available for all-wheel drive vehicles)

•Modified rear axle guide

•New steering for better vehicle dynamics

•Multifunction steering wheel

•Instrument cluster in two variants with FleetBoard® Eco Support

•Broader range of light alloy rims from Daewoo and Alcoa

W26.10-1169-00

• Headlamps in new design with halogen or LED daytime Shift-by-wire switching unit running lamps, stone impact protection, folding (SA for

construction vehicles)

•New transfer case (VG 1000)

•Permanent or shift-on-the-fly four wheel drive

•Wide selection of engine power take-offs at front, for example, for the operation of Frigo alternator

W35.10-1063-00

Rear axle guide

Distribution haulage/ Construction vehicle

Overview of model designations

Distribution haulage/ Construction vehicle

Overview of model designations

Equipment

Equipment packages

In addition to the basic equipment and the various standard equipment packages installed according to the vehicle model/intended use, a number of additional safety and comfort features are also available. These are bundled in packages that are coded at the factory, such as:

•Cold Climate Pack Basic (Z0U)

•Cold Climate Pack Classic (Z0V)

•Cargo liftgate package (P0L)

•LED light package in the front, with turn signal glasses, white (L1Y)

W68.20-1032-00

Stowage box/tray above windshield, 2 compartments (D7M)

W68.20-1031-00

Stowage box/tray, high, on engine tunnel (D7Q)

Equipment

Cockpit

The cockpit is available in three variants depending on the requirements based on the application:

•Classic cockpit (D4B), standard

•Standard cockpit (D4A), special equipment, standard for center seat, with seat belt (D1Z)

•Comfort cockpit (D4C), special equipment

W46.10-1041-00

Multifunction steering wheel for comfort cockpit (D4C)

W68.10-1107-00

Classic cockpit (D4B)

Engines

Engines

Technical data

1 at maximum output

BBNote

It is mandatory that the engine brake for high-perfor- mance system (M5V) is installed on vehicles carrying dangerous goods (ADR code E5T, E5U, E5V, E5W, E5X, E9E) with OM 934.

Engines

Performance graphs

Engines

Performance graphs

Engine power take-off

Front engine power take-off

Fuel system

Clutch

Clutch

Assignment clutch — transmission — engine

P = Output [kW]

M =Torque [Nm]

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