Mercedes-Benz Actros 963 Instruction Manual

Towing and Recovery·Actros, Antos (Model 963), Arocs (Model 964)
Towing and Recovery
Actros, Antos (Model 963)
Arocs (Model 964)
Guidelines for Breakdown Services

Daimler AG · GSP/OR · D-70546 Stuttgart
Mercedes-Benz Service
Towing and Recovery
Actros, Antos (Model 963), Arocs (Model 964)

2 Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
Contents
Preface 4
General description 5
Safety and liability information 5
Vehicle identication 6
Ignition lock 7
Instrument panel 8
Instrument cluster 9
Indicator lamps 10
Safety systems 11
Maintenance ap 12
Electrical system 13
Battery box 13
Jump starting 14
Battery disconnect switch 16
Electrical fuses 17
Tilting the cab 19
Important safety information 19
Before tilting the cab 20
Mechanical/hydraulic cab tilt system 21
Electrohydraulic cab tilt system 22
Starting/stopping the engine with the cab tilted 24
Bleeding the fuel system 25
Bleeding vehicles with fuel prelter 25
Bleeding vehicles without fuel prelter 26
Gearshi󾤩 28
Overview of transmissions 28
Mercedes PowerShi󾤥 backup drive mode 29
Mercedes PowerShi󾤥 neutral shi󾤥 30
Manual transmission emergency shi󾤥 31
Emergency shi󾤥 mode of transmission-independent power take-o󹦕 (NMV) 32
Hydraulic auxiliary drive 35
General information 35
Turbo retarder coupling 36
General information 36
Compressed air system 37
Filling the compressed air system from an external source 37
Emergency lling of the compressed air system 38
Activatable brake 39
Releasing the spring-loaded parking brake 40
Level control 42
Tow-starting 44
Tow-starting the vehicle 44

3Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
Contents
Recovery 46
General information 46
Safety components 47
Maximum permissible pulling forces 48
Towing 49
General information 49
Blocked drive train 53
Engine, transmission and/or axle damage 54
Propeller sha󾤥 removal 55
Drive sha󾤥 removal 56
Towing with a tow bar 58
Towing in raised position 60
Specialtools 68
Mercedes-Benz special tools 68
Shop-made special tools 69
Annex 70
Abbreviations 70
Index 71
Information and copyright 73

4 Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
Preface
Dear Reader,
The aim of these guidelines is to provide roadside assistance
and to provide towing personnel with the instructions and
information necessary in order to remove the vehicle from
the scene of the breakdown or accident within 30 minutes
whenever possible.
The instructions in these guidelines, in particular those
pertaining to vehicle recovery, are intended exclusively for
experienced recovery specialists and are le󾤥 to the discretion
of the user.
All of the data in this brochure correspond to the technical
status as of the copy deadline in December 2015 and may
therefore di󹦕er from the current production conguration.
Daimler AG
Kundendienst Wörth, TE/SCH
December 2015
Contact person
Boris Himmelsbach
TE/SCH, Technical Author
Telephone: [phone]
[e-mail]
b Note
Information about the vehicles and about operating
the vehicle functions can also be found in the interac-
tive owner's manual on the Internet at:
www.mercedes-benz.de/betriebsanleitung
Conventions
$Warning
%Environmental note
ËPotential damage
bNote
MProcedural instruction
Display On-screen display

5
Safety and liability information
General description
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
These guidelines assume that the reader understands and
complies with the pertinent accident prevention regulations,
any relevant professional guidelines for vehicle ownership
or recovery and towing company association regulations,
and the road tra󹦖c regulations of the country in question.
Compensation and/or warranty claims arising from towing
or recovery measures will not be accepted by Daimler AG.
If you are towing the vehicle raised at the front, do not run
the engine and always switch the electronic ignition lock to
position 0.
$WARNING
Modications to electronic components, their so󾤥-
ware or wiring can impair their functioning and/or the
functioning of other networked components. Safety-
relevant systems in particular may also be a󹦕ected.
Because of this, they may no longer function properly
and/or compromise the operational safety of the ve-
hicle. There is a heightened risk of accident and injury!
Never carry out any modications to the wiring and
electronic components or their so󾤥ware. Always have
work on electrical or electronic components or their
so󾤥ware performed at a qualied workshop.
$WARNING
All vehicles that have been towed or recovered from
a breakdown must be examined for technical condi-
tion and checked for damage at a qualied workshop
which possesses all the expertise and tools required
to properly perform the necessary work.
Always observe the information on page46.

6
Vehicleidentication
General description
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
Locationofidenticationplate/vehicleidentication
number
L cab (Actros)
:Model plate
; Vehicle identication number on right longitudinal frame member
Informationontheidenticationplate
:Vehicle manufacturer (Daimler AG)
;EC operating permit number (only for certain countries)
= Vehicle identication number (VIN)
? Permissible gross vehicle weight(kg) Permissible gross combination
weight(kg)
APermissible axle loads of axles 1 to 4 (kg)
BPermissible load of axle group T (kg)
CSmoke index
DRear axle ratio
EBasic headlamp setting
FVehicle model (vehicle model designation)

7
Ignition lock
General description
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
Depending on the vehicle equipment, either an electronic
ignition lock or a mechanical ignition lock may be installed.
The electronic ignition lock consists of the key slot;for ac-
cepting the key= and the two-stage start/stop button:.
To switch the electronic ignition lock, insert the key=all
the way into the key slot;. Insert the key=into the key
slot with the Mercedes star facing upwards.
The electronic ignition lock has the following switch
positions:
• 0
Insert key=.
The ignition and the instrument cluster display are o󹦕.
• 1- Radio position.
Power supply for some consumers.
• 2- Drive position.
The ignition is switched on. The instrument cluster display
shows a menu window or an event window.
• 3- Starting position.
When the key=is inserted and you press the start/stop
button:all the way down, you switch the electronic ig-
nition lock to position3and start the engine.
When the key=is inserted and you press the start/
stop button:as far as the 1st switching threshold, you
switch the electronic ignition lock to the next position 0,
1and 2. If you press the start/stop button in position2,
you switch the electronic ignition lock back to position0.
Performing one of the following actions while the vehicle is
stationary will switch the engine o󹦕:
• Press the start/stop button:all the way down. The
electronic ignition lock is then in position1.
• Press the start/stop button: as far as the 1stswit-
ching threshold and then release it. The electronic igni-
tion lock is then in position1.
• Remove the key=from the key slot. The electronic igni-
tion lock is then in position0.
Key positions in mechanical ignition lock
When you remove the key in position0, the steering is
locked.
b Note
The brochure describes all the switch positions on the
electronic ignition lock.
uTo insert/remove the vehicle key
1Steering wheel unlocked/radio position
2Drive position
3Start position
Switch positions of electronic ignition lock

8
Instrument panel
General description
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
Instrument panel (Actros)
:Exterior lights switch
;Instrument cluster
=Multifunction steering wheel
?Right multifunction control lever
AHazard warning system switch
BElectronics compartment cover
CParking brake
DElectronic ignition lock
EHorn
FMultifunction steering wheel adjuster
G Le󾤥 multifunction control lever

9
Instrument cluster
General description
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
Instrument cluster with additional indicators (Actros)
:Speedometer
;Multifunction display
6Driver airbag
7Driver seat belt reminder
·Emissions-relevant malfunction of BlueTec® exhaust a󾤥ertreatment or
AdBlue®supply too low
5Oil pressure low (engine)
4Oil level too low (engine)
,Coolant level too low
#Battery charge low or malfunction
ªPower supply malfunction
¯Service date due
}Leading axle raised
¡Trailing axle raised
å Starting-o󹦕 aid switched on
ÕSteered trailing axle centered
{ Trailing axle steering angle di󹦕erence
¬ Cargo li󾤥gate open
hTire pressure monitor warning
¨Tire pressure monitor
¦Oil level too low (hydraulic power steering)
D(Yellow) Auxiliary steering/electric power steering
D(Red) Electric power steering fault
£ Sensed 󾤥h wheel coupling not locked
¤ Sensed 󾤥h wheel coupling locked
î Sensed 󾤥h wheel coupling malfunction
. Power take-o󹦕 switched on
x Frequent-stop brake switched on
yPermanent brake malfunction
! ABS equipment
ßTrailer/semitrailer ABS malfunction
ÛTrailer/semitrailer brake system malfunction
©Brake wear limit exceeded
¯Trailer/semitrailer ESP®control intervention
=Tachometer
?AdBlue®level
ATotal distance and trip distance
BClock and outside temperature indicator
CFuel level

10
Indicator lamps
General description
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
Instrument cluster with additional indicators (Actros)
:Warning/indicatorlampsinspeedometer
;Engine diagnosis malfunction
ºCab lock not locked
¸Level control outside driving level
i Di󹦕erential lock switched on
W Braking request at high engine speed
;Turn signals
=Warning/indicatorlampsintachometer
¿Hill holder engaged
l Active Brake Assist 2 switched o󹦕
ÁStability Control Assist control/malfunction
k Stability Control Assist switched o󹦕
À ASR (acceleration skid control) switched o󹦕/control/malfunction
!ABS (anti-lock braking system) control/malfunction
JBrake system malfunction
?Warning/indicatorlampsinAdBlue®gauge
 Diesel particulate lter malfunction
É Diesel particulate lter, automatic regeneration
AWarning/indicatorlampsbelowmultifunctiondisplay
KHigh beams switched on
ÃPermanent brake switched on
!Parking brake applied
UStanding lights switched on
XFluid clutch
FHydraulic auxiliary drive

11
Safety systems
General description
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
General information
When you switch the electronic ignition lock to position 1,
the safety systems are activated automatically.
MSwitch electronic ignition lock to position 1.
SwitchingASR(accelerationskidcontrol)o󹦛/on
MPress buttonà.
When the indicator lampÀin the instrument cluster lights
up, ASR is switched o󹦕.
SwitchingStabilityControlAssisto󹦛/on
MPress buttonk.
When the indicator lampkin the instrument cluster
lights up, Stability Control Assist and ESP®are switched
o󹦕.
SwitchingABA(ActiveBrakeAssist)on/o󹦛
MSwitchingo󹦛: Press top of buttonl.
When the indicator lamplin the instrument cluster
lights up, ABA is switched o󹦕.
MSwitching on: Hold down top of buttonlfor approx.
1 second.
When the indicator lamplin the instrument cluster
goes out, ABA is switched on.
ASR switch (Actros)
Stability Control Assist Switch (Actros)
Active Brake Assist Switch (Actros)

12
Maintenanceap
General description
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
The release levers; are located in di󹦕erent positions de-
pending on the equipment installed:
• VariantA: The release levers; are located on the le󾤥
and right beside the Mercedes star.
• VariantB: The release levers;are located under the
side panels above the headlamps.
MOpeningvariantA: Push both release levers;outwards
in direction of arrow.
MOpeningvariantB: Push le󾤥 and right release levers;
one by one in direction of arrow.
MSwing maintenance ap:upwards.
MClosing: Swing maintenance ap:downwards until it
locks audibly. Maintenance ap variant A (Actros)
Maintenance ap variant B (Actros)

13
Battery box
Electrical system
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
$WARNING
Battery acid is corrosive. There is a risk of injury!
Avoid all contact with your skin, eyes or clothing. Do
not inhale battery gases. When performing mainte-
nance work on the battery, wear acid-proof protective
clothing, particularly safety glasses, protective gloves
and an apron. Do not lean over the battery. Keep chil-
dren away from batteries. If you have come into con-
tact with battery acid, observe the following:
Immediately rinse the battery acid o󹦕 your skin tho-
roughly with plenty of clean water and seek medical
attention without delay.
If you have got battery acid in your eyes, immediately
ush them out thoroughly with plenty of clean water.
Seek medical attention without delay.
Location of batteries
The batteries are located side by side or stacked in the rear
area between the longitudinal frame members or on the side
of the frame.
Cover
MRemoving: Open latch; and remove cover:upwards.
MInstalling: Fit cover:.
MEngage and close latch;.
Vehicle with side-by-side batteries
Vehicle with stacked batteries
Vehicle with integral rear end
Vehicle with integral rear end
Important safety information

14
Jump starting
Electrical system
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
Important safety information
$WARNING
An explosive gas mixture can escape from the battery
when charging and when jump starting. There is a risk
of explosion!
Avoid all re, open ames, sparks and smoking. En-
sure adequate ventilation when charging and when
jump starting. Do not lean over the battery.
$WARNING
Discharged batteries may freeze at temperatures
around the freezing point. If you jump start or charge
the battery, an explosive gas mixture can escape from
it. There is a risk of explosion!
Always let a frozen battery thaw out before charging it
or jump starting.
ËObserve the following instructions, otherwise you
could damage the batteries or electronic components:
• Do not use a quick charger for jump starting.
• If you are using a mobile charger (batteries with
power supply unit), pull the mains plug before
jump starting.
• Only jump start from vehicles with a 24V system.
• Use jumper cables that are protected against
reverse polarity and have a cross section of about
35–50mm² and insulated terminal clamps.
• If the outside temperature has dropped below
-10°C, discharged batteries may freeze. In this
case, do not start the engine. Let the batteries
thaw out rst.
ËDo not connect the negative terminal clamp of the
jumper cable to the chassis frame. The engine,
transmission or electrical and electronic components
could otherwise be damaged.
ËWhen removing the jumper cables, leave the engine of
the power-receiving vehicle running at idle. This avoids
damaging the electrical and electronic components in
the vehicle.
A󾤥er jump starting, have the batteries checked at a qualied
workshop.
Preparation for jump starting
MMake sure that the vehicles do not touch each other.
MApply parking brake.
MSwitch o󹦕 all electrical consumers.
MSwitch electronic ignition lock to position 0.

15
Jump starting
Electrical system
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
Connecting the jumper cables
MRemove cover, see page13.
MClip the positive terminal clamp of the jumper cable rst
to the positive terminal of the booster battery and then to
the positive terminalqof the starter battery.
MClip the negative terminal clamp of the jumper cable rst
to the negative terminal of the booster battery and then
to the negative terminal±of the starter battery.
MRun the engine of the vehicle supplying power at a high
speed.
MStart engine and run at idle speed.
MOnly switch on inductive loads (e.g. the seat heater) in
the vehicle supplying power.
MIf the battery charge is very low: Leave the jumper
cables connected for a few minutes with the engine
running.
Disconnecting the jumper cables
MUnclip the negative terminal clamps of the jumper cable
from the negative terminals rst.
MUnclip the positive terminal clamps of the jumper cable
from the positive terminals.
Connecting the jumper cables
MClip the positive terminal clamp of the jumper cable to
the positive terminal of the booster battery rst.
MPush back the red cap with the positive terminal clamp of
the jumper cable and clip it onto the positive terminal.
MClip the negative terminal clamp of the jumper cable to
the negative terminal of the booster battery rst.
MPush back the black cap with the negative terminal clamp
of the jumper cable and clip it onto the negative terminal.
MRun the engine of the vehicle supplying power at a high
speed.
MStart engine and run at idle speed.
MOnly switch on inductive loads (e.g. the seat heater) in
the vehicle supplying power.
MIf the battery charge is very low: Leave the jumper
cables connected for a few minutes with the engine
running.
Vehicles with jump-start connection point
Vehicles without jump-start connection point
Vehicle with side-by-side batteries
Vehicle with jump-start connection point
Disconnecting the jumper cables
MUnclip the negative terminal clamps of the jumper cable
from the negative terminals rst. The black cap on the
jump-start connection point springs back to its default
position.
MRemove the positive terminal clamps of the jumper cable
from the positive terminals. The red cap on the jump-start
connection point springs back to its default position.

16
Battery disconnect switch
Electrical system
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
General information
$WARNING
When you interrupt the power supply with the battery
disconnect switch, the engine is switched o󹦕 automa-
tically. Because of this, some safety-relevant functions
will be limited or no longer available, e.g. the power
steering, the lights and the ABS. The compressed air
system is not lled any more. You will require consi-
derably more e󹦕ort to steer. The wheels may lock up
when braking. Also, if there is a leak of compressed
air, the spring-loaded parking brake may activate and
the vehicle may perform uncontrolled braking actions.
You could lose control of the vehicle. There is a risk of
accident!
Do not operate the battery disconnect switch until the
vehicle is stationary.
The battery disconnect switches are used to interrupt the
power supply. This prevents short circuits with arcing which
could trigger a re or explosion. Vehicles used to transport
hazardous goods are equipped with 2 battery disconnect
switches depending on their ADR classication. Once the
vehicle has been parked safely, you can use the battery dis-
connect switches, e.g. when loading a vehicle in a hazardous
goods zone. Only use the battery disconnect switch with
the vehicle stationary. Observe the information in the event
window of the onboard computer.
Switch the electronic ignition lock to position 0and remove
the key from the key slot. On vehicles with retarder, wait
for roughly 5 seconds a󾤥er switching o󹦕 the ignition before
you interrupt the power supply with the battery disconnect
switch. If the auxiliary heater was switched on, wait until the
power-down of the auxiliary heater has nished.
In a hazardous situation, you can interrupt the power supply
immediately with the battery disconnect switches. If you
interrupt the power supply with the battery disconnect switch
while the anti-the󾤥 alarm system is active, the anti-the󾤥
alarm system triggers an alarm.
Interrupting the power supply
MFlip the cover :up.
MPull out the switch stalk; or ip the switch stalk=
upwards.
All consumers are disconnected from the battery, with the
exception of the tachograph.
Restoring the power supply
MPress the cover :downwards and engage.

17
Electrical fuses
Electrical system
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
General information
$WARNING
Blown fuses and defective circuit breakers must be re-
placed with equivalent fuses with the ratings specied
in the fuse assignment diagram. Fuses of the same
rating are the same color. Further information can be
obtained from any Mercedes-Benz Service Center.
$WARNING
Tampering with defective fuses, bridging them or
replacing them with fuses of a higher amperage can
overload the electrical lines. This can result in a re.
There is a risk of accident and injury!
Only replace defective fuses with the specied fuses
of the correct amperage.
The individual circuits are protected by fuses or circuit brea-
kers. Other circuits, e.g. the lights, are fused via electronic
control units. If there is a malfunction, the electronic control
unit switches the consumer o󹦕.
MIf a circuit fails, switch o󹦕 the consumer and switch the
ignition lock to position 0.
MSwitch electronic ignition lock to position 2.
MSwitch consumer on again.
The electronic control unit checks the circuit. If there is no
malfunction, the electronic control unit switches the consu-
mer back on.
The fuse assignment diagram is located on the inside of the
electronics compartment cover.
MSwitch o󹦕 consumer and switch electronic ignition lock to
position 0.

18
Battery disconnect switch
Electrical system
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
Removing the cover of the electronics compartment
MOpen latches ;and remove cover :.
Location of fuses
:Module A32 (relays)
;Base module (SCA)
(fuses, relays and diodes)
=Module A31 (relays)
?Modules A1 and A2 (fuses)

19
Important safety information
Tilting the cab
Towing and Recovery | Actros, Antos (Model 963), Arocs (Model 964)
$WARNING
The cab may suddenly drop into the end position or
back to its original position when it is being tilted.
There is a risk of injury to any persons within the tilting
range of the cab!
Only tilt the cab when you are certain that nobody is
standing in the tilting range. Do not stand under the
cab when it is in the tilted position.
ËIf you need to open a door when the cab is tilted,
it must be moved carefully and slowly to the end
position. The A-pillar or the door hinge could
otherwise be damaged.
ËDo not turn the steering when the cab is tilted. The
restricted articulation angles could damage the
universal joints.