Trucks Overall Vehicle - On-Board Electrical System, Bus System On-Board Electrical Systems, System Networking, Instruments Run Trainer Document

Global Training – The finest automotive learning
Trucks · Overall Vehicle - On-Board Electrical

System, Bus System
On-Board Electrical Systems, System
Networking, Instruments · Run
Trainer Document
NEBN-ME263
As at 11.2.2011
This document is intended for use in the training only. Performed exercises cannot simply be implemented in practice. Coun-
try-specific laws, regulations and specifications must always be observed.
The training documents are not subject to the ongoing update service. For work at the vehicle, the most up-to-date work-
shop aids (e.g. EPC net, WIS net, DAS, special tool) of the manufacturer for the affected vehicle must be used.
Printed in Germany
© 2011 Copyright Daimler AG
Publisher: Global Training
This document, including all its parts, is protected under the laws of copyright. Any further processing or use requires the
previous written consent of Daimler AG. This applies in particular to reproduction, distribution, alteration, translation, micro-
filming and storage and/or processing in electronic systems, including databases and online services.
Note: The term 'employee' always refers to both female and male members of staff.
1511 8410 - 1st edition 11.2.2011 218

Contents
Contents
1 Orientation .................................................................................................................1
Instructions..................................................................................................................................... 1
1.1 Welcome............................................................................................................................... 2
2 Model Series Overview...............................................................................................3

Instructions..................................................................................................................................... 3
2.1 Overview............................................................................................................................... 4
2.2 Atego2/Axor2 Model Designations ...................................................................................... 4
2.3 ACTROS Model Designations................................................................................................ 6
3 Power Distributor .......................................................................................................7

Instructions..................................................................................................................................... 7
3.1 Power Distributor.................................................................................................................. 8
3.2 Actros MP3 Battery Sensor................................................................................................. 10
3.3 Installation Locations of Control Units................................................................................ 13
4 Practical Work 1.......................................................................................................16

Instructions................................................................................................................................... 16
4.1 Atego2/Axor2 Power Supply .............................................................................................. 17
4.2 Actros3 Voltage Curve........................................................................................................ 18
4.3 Comparison of Practical Exercises...................................................................................... 20
5 Networking...............................................................................................................21
Instructions................................................................................................................................... 21
5.1 ATEGO2/AXOR2 Networking.............................................................................................. 23
5.2 Networking in the ACTROS ................................................................................................ 25
5.3 Diagnostic Socket X13 ....................................................................................................... 28
5.4 CAN Fundamentals ............................................................................................................. 29
6 Practical Work 2.......................................................................................................36

Instructions................................................................................................................................... 36
6.1 Networking ......................................................................................................................... 37
7 Practical Work 3.......................................................................................................39

Instructions................................................................................................................................... 39
7.1 Emergency Limp-home Concept in Actros3........................................................................ 40
7.2 CAN Measurement on the Model........................................................................................ 42
NEBN-ME263 <> Trainer Document I

Contents
8 Instrument................................................................................................................45
Instructions .................................................................................................................................. 45
8.1 Instrument.......................................................................................................................... 47
8.2 Instrument 2004 ................................................................................................................ 47
8.3 New ATEGO/AXOR Instrument .......................................................................................... 50
8.4 Instrument 2008 ................................................................................................................ 52
9 Practical Work 4.......................................................................................................59

Instructions .................................................................................................................................. 59
9.1 Driver Information System FIS in the Actros3 .................................................................... 60
9.2 Parameterization of INS in the Atego2/Axor2.................................................................... 62
9.3 Steering Wheel Buttons at the Model ................................................................................. 64
9.4 Comparison of Practical Exercises ..................................................................................... 65
10 Base Module ............................................................................................................66

Instructions .................................................................................................................................. 66
10.1 Base Modules..................................................................................................................... 67
10.2 Atego2/Axor2 Base Module............................................................................................... 67
10.3 Base Module in Actros........................................................................................................ 70
10.4 Central Data Memory / Mirror Memory ............................................................................. 72
11 Practical Work 5.......................................................................................................74

Instructions .................................................................................................................................. 74
11.1 Signal Path ......................................................................................................................... 75
11.2 Comparison of Practical Exercises ..................................................................................... 79
12 Trailer Socket...........................................................................................................80
Instructions .................................................................................................................................. 80
12.1 Trailer Socket ..................................................................................................................... 81
12.2 Cotel Interface.................................................................................................................... 83
12.3 Modular Switch Panel (MSF) .............................................................................................. 84
13 Practical Work 6.......................................................................................................91

Instructions .................................................................................................................................. 91
13.1 Modular switch panel ......................................................................................................... 92
14 Exterior Lighting .......................................................................................................94

Instructions .................................................................................................................................. 94
14.1 Exterior Lights on the ATEGO2/AXOR2.............................................................................. 95
14.2 Exterior Lights on the ACTROS ........................................................................................... 97
15 Exterior Lamp Failure Monitor................................................................................101

Instructions ................................................................................................................................ 101
II NEBN-ME263 <> Trainer Document

Contents
15.1 Bulb Failure Monitor in the Atego2/Axor2........................................................................ 102

15.2 Bulb Failure Monitor in the Actros .................................................................................... 103
16 Practical work 7 .....................................................................................................105

Instructions................................................................................................................................. 105
16.1 Possibilities of Fault Detection by Control Units............................................................... 106
17 Door Module ..........................................................................................................111

Instructions................................................................................................................................. 111
17.1 Door Control Panel in ATEGO2/AXOR2 ............................................................................ 112
17.2 Door Module in Actros...................................................................................................... 113
18 Rain/Light Sensor (RLS), Connective Logics .........................................................115

Instructions................................................................................................................................. 115
18.1 Rain/Light Sensor (RLS) ................................................................................................... 116
18.2 Function Pins .................................................................................................................... 120
19 Battery Disconnect Switch.....................................................................................124

Instructions................................................................................................................................. 124
19.1 Battery Disconnect Switch in GGVS vehicles (hazardous goods vehicles) ........................ 125
19.2 Battery Disconnect Switch in the ATEGO2 / AXOR2 ........................................................ 125
19.3 GGVS Functions in the Actros........................................................................................... 129
20 Antennas ................................................................................................................131
Instructions................................................................................................................................. 131
20.1 Antennas .......................................................................................................................... 132
21 Practical Work 8.....................................................................................................135

Instructions................................................................................................................................. 135
21.1 Wiring Diagram Exercise for GGVS Axor2 ......................................................................... 136
21.2 Troubleshooting at the Axor2 ........................................................................................... 138
21.3 Parameter Setting at Function Pin 17............................................................................... 139
21.4 Comparison of Practical Exercises.................................................................................... 140
22 Retrofitting Electrical Consumers ..........................................................................141

Instructions................................................................................................................................. 141
22.1 Notes on Product Liability................................................................................................. 143
22.2 Rules of Conduct for Retrofit Work on Electrical Consumers............................................ 144
22.3 Cable Passages................................................................................................................. 146
22.4 Retrofitting Control Units.................................................................................................. 147
22.5 Retrofitting Indicator Lamps in the Instrument ................................................................. 148
22.6 Adapter Cable and Y-cable................................................................................................ 149
22.7 Retrofitting Switches ........................................................................................................ 150
NEBN-ME263 <> Trainer Document III

Contents
23 Voltage Sources .....................................................................................................151

Instructions ................................................................................................................................ 151
23.1 Voltage Sources at the ATEGO2/ AXOR2......................................................................... 153
23.2 Voltage Sources at the ACTROS2/3 ................................................................................ 156
23.3 Power Supply in Trailer/Semitrailer Greater than 10 A .................................................... 159
23.4 12 V Voltage Converter .................................................................................................... 160
23.5 Practical Work on Voltage Converters .............................................................................. 161
24 Power Take-off via Base Module ............................................................................162

Instructions ................................................................................................................................ 162
24.1 Power Take-off via Base Module....................................................................................... 163
25 Practical Work 9.....................................................................................................167

Instructions ................................................................................................................................ 167
25.1 Retrofitting on the ACTROS3/AXOR2 .............................................................................. 168
25.2 Retrofitting the Modular Switch Panel.............................................................................. 170
25.3 Power Take-off via Base Module at the ACTROS3 ............................................................ 172
25.4 Comparison of Practical Exercises ................................................................................... 175
26 Compulsory Lowering and Residual Air Bellows Pressure regulation.....................176

Instructions ................................................................................................................................ 176
26.1 Compulsory Lowering via Base Module ............................................................................ 177
26.2 Residual Air Bellows Pressure Regulation via Base Module.............................................. 178
26.3 Compulsory Lowering and Residual Air Bellows Pressure Regulation via PSM ................. 179
27 Cargo Liftgate ........................................................................................................180

Instructions ................................................................................................................................ 180
27.1 Cargo Liftgate Preinstallation ........................................................................................... 181
27.2 Cargo Liftgate................................................................................................................... 182
28 Conclusion .............................................................................................................183
Instructions ................................................................................................................................ 183
28.1 Final Discussion ............................................................................................................... 184
NEBN-ME263 Trainer Preparation ...............................................................................185

Daily agenda............................................................................................................................... 185
IV NEBN-ME263 <> Trainer Document

1 Orientation
0 Instructions
1 Orientation
Instructions
Overall duration.................................................................................................................45 min.
1.1 Welcome
Structured card questions 10 min

Visualize statements with
participants
Introduction round
Mutual familiarization
Partner interview with metaplan cards 20 min.
Training overview
The participant can name the contents of the comfort and passive safety training
Overview of comfort and passive safety training
Interactive lecture 5 min.
Game Rules
Define common rules of the game
5 min.
Training schedule
The participant can name the contents and the training agenda.
Training agenda
NEBN-ME263 <> Trainer Document 1

1 Orientation
1.1 Welcome
1 Orientation (Participants)
1.1 Welcome
Welcome to the training course on the
Atego2, Axor2, Actros2 and New Actros (in the documents referred to as the Actros3) on-board
electrical systems, system networking and instruments.
We will work through the current on-board electrical system of Mercedes-Benz commercial ve-
hicles in this training to keep you up to date on the increasingly complex networking of the
electrical and electronic components.
Good luck!
2 NEBN-ME263 <> Trainer Document

2 Model Series Overview
0 Instructions

Instructions
Total time ...........................................................................................................................20 min
2.1 Overview
Overview of Atego2, Axor2, Actros2/3
2.2 Atego2/Axor2 Model Designations
The participant can understand the model designations

The participant can identify the vehicle by means of the VIN
The participant can assign the workshop literature to model designations
Get to know the model designations and enumerate the differences from the
Atego1/Axor1 through to the Atego2/Axor2
2.3 Actros Model Designations
The participant can understand the model designations

The participant can identify the vehicle by means of the VIN
The participant can assign the workshop literature to model designations
Get to know the model designations and enumerate the differences from the Actros1
through to the Actros3

2.1 Overview
2 Model Series Overview (Participants)

2.1 Overview
Up to now the design of on-board electrical systems was practically identical for all Mercedes-
Benz trucks. This changed with the introduction of the ACTROS2. It has more system compo-
nents than the ATEGO2 or AXOR2. In the ACTROS2 the electrical/electronics concept is desig-
nated KONTACT (concept of the electrical system/ electronics network in the Actros). This
concept also applies for the model-refined ACTROS3.
Another distinct difference can be found in the engines: in the ACTROS only V-engines are
used, whereas inline engines are used in the other models.
In all vehicles the on-board electrical system comprises a conventional and a networked part.
Atego2
Axor2R
ACTROS2/ACTROS3
Axor2C

Model designation overview for the Wörth production plant in Germany
The sales designation of the previous Atego up to 15 t changes to ATEGO2. The designations
Atego 18 t and over and Axor are combined as AXOR2. The familiar vehicle model designations
have been kept. The cab model designation helps to recognize the new vehicles. 9.. 899 was
changed to 9.. 890. The model series 944 is produced both in the Wörth plant in Germany and
in the Aksaray plant in Turkey.

Sales designations ATEGO2 AXOR2

Internal designations ATEGO2 Axor2R Axor2C
Code XV1 XV2 XV3
Model designation for 970/972/974/976 950/952/953/954 940/944
Wörth plant (WDB)
Model designation for 375.1 375.3 375.4
Aksaray plant (WDF)
Models 712 – 2228 1823 - 2633 1835 - 2543
Engines OM904 LA/OM906 LA OM906 LA/OM926 LA OM457 LA
Cab model designa- 972.890 940.890 944.890
tion
Note
If an Axor is produced in Turkey commissioned by the Wörth plant, the VIN begins with
WDF followed by the model designation no. 950-954 or 940-944.

2.3 ACTROS Model Designations
2.3 ACTROS Model Designations

The model codes in the vehicle ID number for the ACTROS2 have been changed from 950-954
to 930-934 for better differentiation. The model designation codes were kept the same. The
model code of the ACTROS2 was retained with the introduction of the ACTROS3.
ACTROS ACTROS2/3 Engine Vehicle version
950 930 OM501 LA, OM502 LA Platform trucks
952 932 OM501 LA, OM502 LA Dumper trucks
953 933 OM501 LA, OM502 LA Concrete mixers
954 934 OM501 LA, OM502 LA Semitrailer tractors
Model plate N_58.00-002024-SW
The ACTROS2/3 cabs

In order to meet the usage requirements of the various branches and businesses, the AC-
TROS2/3 is available in different cab variants (S, M, L and LH cabs).

3 Power Distributor
0 Instructions
3 Power Distributor
Instructions
Total time ...........................................................................................................................30 min
3.1 Power Distributor
The participant can describe the task of the power distributor

The participant can state the possible expansions
The participant can state the possible installation locations
The participant can describe the procedure in jump starting
Actros3 power distributor
Interactive lecture 10 min

Presentation
3.2 Actros MP3 Battery Sensor
The participant can describe the task of the battery sensor.

The participant can state the display possibilities in the Instrument.
Actros MP3 battery sensor

Presentation
3.3 Installation Locations of Control Units
The participant can name the installation locations for the control units
The participant can name the major CAN bus systems
The participant can assign abbreviations and terms to the network using the info sheet
Installation locations of the Atego2, Axor2 and Actros2/3 control units

Presentation

3 Power Distributor
3 Power Distributor (Participants)

For vehicles with integral rear end, the path from the battery compartment to the starter is
twice as long. For this reason, the battery lines for these vehicles are split in two and the line
cross-sections are increased. A separation point is provided in the frame for ease in assembly
of the lines.
For vehicles with integral rear end, it is possible to perform jump-starts at the power distributor
(see arrows) in the event of a breakdown, since it is not possible to jump-start a hitched-up ve-
hicle directly at the batteries.
The integral rear end version is also used on the Axor2 with the equipment "right-hand drive
with fifth wheel coupling and leading axle".
Integral rear end N_54_10_002049_SW
Power distributor installation location with integral

rear end 54_10_x
Power distributor without integral rear end
GT54_10_0009
3.1.1 Current Tap on the Power Distributor

Additional junction boxes that are simply plugged into the existing power distributor are pro-
vided for the current tap at the frame. Further positive and ground potentials can also be
tapped in the distributors. The positive line is protected by a fuse. Depending on the require-
ments, up to three additional taps may be performed.
Maximum tap for all additional taps: 200 A

3 Power Distributor
Power distributor TT_54_10_006581_FA

3 Power Distributor

IBS = Integrated Battery Sensor
The integrated battery sensor is being factory-installed in the Actros MP3 as of 10/2010.
The introduction of the integrated battery sensor was necessitated by the increased energy re-
quirement.
To secure vehicle starting capability (avoidance of empty batteries), a system is used to inform
the driver about the charge level and starting capability of the batteries.
The information is delivered by the battery sensor.
TT_54_10_011119_FA
The integrated battery sensor (IBS) is connected to the LIN bus. It consists of a chip that con-
tains the measuring and electronic analysis system, a shunt (measuring resistance 50 ohms) for
current measurement and a temperature sensor. Together with the terminal clamp it comprises
an assembly unit connected to the ground terminal of the battery.
The measurement values prepared by the electronic system of the battery sensor:
Current
Voltage
Temperature
are sent to the LIN bus master in the base module.
The base module sends the data prepared by the IBS to the instrument cluster via the vehicle
CAN.
Because the battery sensor was taken from passenger car technology (on-board electrical sys-
tem voltage 12 V), the circuitry of the battery sensor had to be adjusted for use in commercial
vehicles with an on-board electrical system voltage of 24 V. The 12 V supply takes place via an
internal voltage regulator in the IBS.
The measurement and analysis procedures (algorithms) are contained in the integrated battery
sensor (IBS) chip. The battery sensor takes over the tasks of detecting voltage, current and
temperature and calculates the battery level and starting capacity from the measurement data.
This data is sent from the base module to the instrument cluster via the vehicle CAN. The si-
multaneous detection of 24 V and 12 V measurement values means that both batteries are
covered.

3 Power Distributor
The voltage value of the second battery is determined from the difference of the two measure-
ment values. The temperature measurement is performed by an NTC resistor. It detects the
battery terminal temperature. The IBS derives the electrolyte temperature of the battery from
the measurement values.
TT_54_10_011120_FA
Macromelt coating (provides protection

1
against water, oils, fuel…)
2 95 mm2 battery cable
Note
The battery type must be parameterized in the base module. After charging, jump-starting or
changing of the battery, the IBS requires 20 driving cycles (engine start -> drive -> engine stop),
to calibrate the new batteries. Before the batteries are calibrated (20 driving cycles), the bat-
tery state may be indicated incorrectly or not at all in the instrument cluster.
With a battery change to a different capacity the new battery type must be parameterized into
the base module.
Several performance maps for the various battery types have been stored in the IBS. The
evaluation of the measured data takes place via the performance maps.
Indication of the starting capability in the instrument cluster display

The battery status is shown as a white bar. The critical range is shown dotted. "Critical" means
that the starting capability of the vehicle is jeopardized by this battery condition. The tendency
of the bar is indicated to the right of the bar, i.e. whether the battery is discharging (arrow
pointing to the left) or whether the battery is charging (arrow pointing to the right). A strong
discharge or charge is indicated by a double arrow.
When the battery level comes close to the dotted range, the driver is warned.

3 Power Distributor
TT_54_10_011121_SW
Display Explanation
A high charging current is charging the batteries.
TT_54_10_011125_SW
A low charging current is charging the batteries.
TT_54_10_011123_SW
A low discharge current is discharging the batteries.
TT_54_10_011122_SW
A high discharge current is discharging the batteries.
TT_54_10_011124_SW

3 Power Distributor

ATEGO2 / AXOR2
The electronics are distributed across two locations in the cab:
Electrical compartment 54_10
Rear panel on co-driver side 54_10
A3 Drive control (FR)

Electrohydraulic auxiliary
A11 Brake system BS A72
steering (EHZ)
A14 NR level control Z2 Terminal point
Parameterizable special mod-
A22
ule (PSM)
A30 Maintenance system (WS)
Hydraulic-pneumatic power
A52
shift (HPS)
Possible electronics in the electrical compartment Possible electronics in the rear panel
ABS Antilock brake system EHZ Electrohydraulic auxiliary steering
AGN Allison automatic transmission FFB Radio remote control
(if the electrical compartment is full)
AGS2 Automatic transmission control 2 KSA Comfort locking system
BS Brake system NR Level control
FFB Radio remote control RD Tire pressure monitor
FLA Flame starting system CL (if the electrical compartment is full)
FR Drive control
GS Transmission control

3 Power Distributor
Possible electronics in the electrical compartment Possible electronics in the rear panel
HPS Hydraulic-pneumatic power shift
Shift force assistance
KSA Comfort locking system
NR Level control
PSM Parameterizable special module
RS Retarder control
SRS Supplemental restraint system
WS Maintenance system
ZHE Auxiliary heater
CL Central locking
ACTROS2/ACTROS3
KontAct components
KontAct (electronic networking concept in Actros) includes all vehicle network control units.
The minimum equipment in KontAct includes the following control units:
Front module FM
Located in the front of the vehicle on the passenger side underneath the cab. All inputs and
outputs from the front area of the vehicle are received and transmitted here. This means that
all sensors and actuators located in the front area are connected to the front module. (except
the brake system and transmission control)
Rear module HM
Located on the right side of the rear axle area in the frame of the vehicle. The rear module
takes over all tasks that have to be controlled and monitored in the rear area of the vehicle.
This means that all sensors and actuators located in the rear area are connected to the rear
module. (except the brake system and transmission control)
Electrical compartment with base module GM
The electrical compartment is located on the passenger side behind the footwell trim. The base
module makes up the central unit for KontAct and has several CAN interfaces. All inputs and
outputs from the cab of the vehicle are received and transmitted here.
Instrument cluster INS
The instrument cluster has become pure display electronics and has few remaining tasks in the
network.
Driver-side door module TMF
Located in the driver door. The driver-side door module control unit is used to control all func-
tions from the area of the driver door.
Passenger-side door module TMB
Located in the passenger door. The passenger-side door module control unit controls all func-
tions from the area of the passenger door.

3 Power Distributor
Modular switch panel MSF
A data bus system located in the cab. All switches are networked with each other and transmit
CAN messages to the MSF. The hazard warning flasher switch is integrated into the control unit
of the modular switch panel. The other switches are distributed across various switch panels in
the cab.

4 Practical Work 1
0 Instructions
4 Practical Work 1
Instructions
Overall duration: ................................................................................................................50 min.
4.1 Atego2/Axor2 Power Supply
The participants can describe the power supply / voltage curve

Group exercise in 2 groups
Group 1 with Actros3
Group 2 with Atego2
Exercises on the vehicle 20 min.
4.2 Actros3 Voltage Curve
The participants can describe the power supply / voltage curve

Group 1 with Atego2
Exercises on the vehicle 20 min.
4.3 Comparison of Practical Exercises

Comparison of practical exercises

Presentation

4 Practical Work 1
4 Practical Work 1 (Participants)

Exercise 1 Take a look at the on-board electrical system of the vehicle in the wiring diagram.
Draw the voltage flow for terminals 30 and 31 to the respective components into the picture.
Begin with the battery and note the respective line cross-sections.
TT_54.00-006319-SW

4 Practical Work 1

Exercise 2 Take a look at the on-board electrical system of the vehicle in the wiring diagram.
Draw in the voltage supply for terminals 30 and 31 to the respective components.
Begin with the battery and note the respective line cross-sections.
Vehicle with integral rear end
54_x
1 Alternator
2 Starter

4 Practical Work 1
Exercise 3 Examine the fuses in the power distributor. State the amperage of the fuse in each case.
FM:
New 60A
Old 80A
BM
Not fused
HM:
New 40A
Old 60A
Exercise 4 Take a look at the wiring diagram for the power supply to the base module in the Actros3.
What is the maximum permissible permanent current?
(maximum current density: 6 A/mm2, with a copper line and a cross-section of 10 to 35 mm2)
Maximum permanent current approx. 96A
Exercise 5 Look at the voltage supply of the modules drawn on the vehicle.
Draw in the voltage supply for terminals 30 and 31.
Begin with the power distributor and note the respective line cross-sections.
Vehicle with integral rear end
TT_54.00-006322-SW
1 Alternator
2 Starter

4 Practical Work 1

• Discussion of the practical exercises in the overall group
• Answer any open questions.

5 Networking
0 Instructions
5 Networking
Instructions
5.1 ATEGO2/AXOR2 Networking
The participant can describe the networking of the Atego2/Axor2

Atego2/Axor2 networking

Presentation
5.2 Networking of Actros
The participant can name the major CAN bus systems.

The participant can understand the names of the basic control units, abbreviations
and terms.
The participant can explain the concepts "virtual control units" and "distributed
functions".
The participant can describe the networking diagram.
The participant can name the major functions of the KontAct control units.
Actros2/3 networking
Virtual control units
Integrated control units
Presentation
5.3 Diagnostic Socket X13
The participant can name the installation locations for the diagnostic sockets
The participant can state the assignment of the diagnostic sockets
Diagnostic socket assignment

Presentation

5 Networking
0 Instructions
5.4 CAN Fundamentals
The participant can name the physical properties of the various CAN bus systems.
The participant can understand the structure of a CAN message.
The participant can understand the CAN priority.
The participant can describe the basic function of the LIN bus.
Neutral points and terminal points,
CAN bus systems,
LIN bus
Presentation

5 Networking
5 Networking (Participants)
ATEGO2/AXOR2 networking TT_54_00_006711_SH

5 Networking
ABS Antilock brake system RS Retarder control
AG Automatic gear selection SCR Selective Catalytic Reduction, BlueTec
AGS2 Automatic transmission control 2 SPA Lane Assistant
AGN Allison automatic transmission SRS Supplemental restraint system
AM Axle modulator TCO Tachograph
ART2 Autonomous intelligent cruise control WS Maintenance system
BS2 Brake system 2 ZHE Auxiliary heater
EAB Electronic trailer brake CAN ZV Central locking
EHZ Electrohydraulic auxiliary steering X13 Diagnostic socket
FDR Driving dynamics control Z1 Star point
FFB Radio remote control Z2 Terminal point
FLA Flame starting Z3 Star point
FR Drive control Z5 Terminal point
GS Transmission control 1 Vehicle CAN bus 500 kBaud
HPS Hydraulic-pneumatic power shift 2 Interior CAN bus 125 kBaud
KB Clutch operation 3 Frame CAN bus 250 kBaud
KS Clutch control 4 Engine CAN bus 125 kBaud
KSA Comfort locking system 5 Transmission CAN bus 250 kBaud
LWS Steering angle sensor 6 Brake CAN bus 500 kBaud

Trailer electronics CAN interface 125
MR Engine control 7
kBaud
Body electronics CAN interface 125
NOX Nitrogen oxide sensor 8
kBaud
NR Level control 9 Telematics CAN bus 250 kBaud
PSM Parameterizable special module 10 Speedometer CAN bus 125 kBaud
RAD Radio 11 CAN interface for trailer 125 kBaud

SCR-CAN on-board diagnosis, CAN 250
RD Tire pressure monitor 12
kBaud

5 Networking
5.2 Networking in the ACTROS

The IES networking (Integrated Electronics System) is the basis for KontAct and has been ex-
tended by additional CAN bus systems. With the extended "KontAct" networking, 12 different
CAN bus systems are used in the ATEGO 2, AXOR 2, and ACTROS. The CAN bus systems are
named after the respective scope of tasks, e.g. frame CAN or interior CAN.
Actros 2/Actros 3 TT_54.00-001704-SW.jp

5 Networking
AM Axle modulator RLS Rain/light Sensor
AG Automatic gear selection RS Retarder control
ANH Trailer electronics CAN interface SCR Selective catalytic reduction
ART2 Autonomous intelligent cruise control 2 SPA Lane Assistant
AUF Body electronics CAN interface SR Stability control
BS Brake system SRS Supplemental restraint system
BTS GGVS battery disconnect switch TCO Tachograph
EAB Electronic trailer brake CAN interface TMF Driver door module
EAPU Electronic Air Processing Unit TMB Front passenger door module
ATA Theft warning system TP Telematics platform
FFB Radio remote control WR Roll control
FLA Flame starting system WS Maintenance system
FM Front module WSK Torque converter clutch
FR Drive control X13 EOBD diagnostic socket
GM Base module CDM Central data memory
GS Transmission control ZHE Auxiliary heater
HM Rear module ZL Auxiliary steering
HZR Heater control Z2 Terminal point 2
IBS Integrated battery sensor Z3 Terminal point 3
INS Instrument Z6 Terminal point 6
KB Clutch operation 1 Vehicle CAN 500 kBaud
KDiag Diagnosis K-line 2 Interior CAN, 125 kBaud
KNot Emergency shift K-line 3 Frame CAN, 250 kBaud
KOM Communications interface 4 Engine CAN, 125 kBaud
KR Clutch control 5 Transmission CAN, 250 kBaud
LWS Steering wheel angle sensor 6 Brakes CAN, 500 kBaud

Trailer electronics CAN interface 125
MSF Modular switch panel 7
kBaud
Body electronics CAN interface 125
MR Engine control 8
kBaud
NR Level control 9 Telematics CAN, 250 kBaud
PSM Parameterizable special module 10 Tachograph CAN, 125 kBaud
RAD Radio 11 CAN interface for trailer 125 kBaud

SCR-CAN on-board diagnosis, CAN 250
RD Tire pressure monitor 12
kBaud

5 Networking
Virtual control units, integrated functions in the Actros

Control units have been combined as part of the extended networking in the ACTROS. This
means that they no longer have their own housing. They only exist as software, and are thus vir-
tual:
• WS (maintenance system)
• KOM (communications computer)
• ATA Antitheft alarm system ()
• ZDS (central data memory)
Note
Virtual control units are not available as components, but they can be selected and worked
on using the diagnostic unit. They behave like control units that exist as hardware.

Some control units were integrated completely into other control units. They are no virtual con-
trol units, since they do not appear in the DAS menu and can also not be called up there. Their
actuation, fault codes and actual values are shown under a new number in another control unit.
The following control units have been integrated:
• AG (automatic gear selection is integrated into the FR (drive control))
• KR (clutch regulation is integrated into the FR (drive control))
• FFB (receiver radio remote control) is integrated into the GM (base module)
• NR (level control) is integrated into the FM (front module) and in the HM (rear module)
• WR (roll control) is integrated into the FM (front module) and in the HM (rear module)
• KB (clutch operating system) is integrated into the GS (transmission control)
Note
Integrated control units are functions that have been incorporated into other control units.
The fault codes can be found in DAS under the new control unit. The access via functions
was added in DAS to make the new control units easier to locate.

5 Networking

The pin assignment of the 16-pin EOBD socket is standardized. (European On Board Diagnosis)
In the ATEGO2/AXOR2 it is located on the driver side next to the steering column. In the Ac-
tros2 it is located on the passenger side above the footwell trim.
Diagnostic socket X13 TT_54_22_005683_FA
Pin assignment X13:

Pin 01 NOT ASSIGNED Pin 09 MR
Pin 02 NOT ASSIGNED Pin 10 AGS2 (only Atego 2
Pin 03 NOT ASSIGNED Pin 11 NOT ASSIGNED
Pin 04 Tml. 31 ground Pin 12 Radio activation (production)
Pin 05 Tml. 31 ground Pin 13 Navigation activation (production)
Pin 06 EOBD CAN high for Pin 14 EOBD CAN low for Z3
Z3
Pin 07 K-line Pin 15 Allison transmission (only Atego 2)
Pin 08 Tml. 15 Pin 16 Tml. 30

5 Networking

K-line:
This is a data line with low data speeds (9.6 kBaud) and is used to connect the Star Diagnosis
to the vehicle.
TT_54_18_005697_SW
Low-speed CAN bus:
The data is transmitted on two twisted lines for the low-speed CAN bus (125 kBaud). 2 ground
lines are used to shield the data lines. These are also twisted with the data lines.
TT_54_18_005698_SW
High-speed CAN bus:
Data is transferred at very high speed on 2 twisted cable (up to 500 kBaud).
TT_54_18_005699_SW
CAN bus messages

• The messages consist of a specific number of bits.
• The content of the information they contain is predefined.
• The addresses and the format of the messages are defined by the "identifier" (e.g. rpm).
• The transfer speeds on the CAN bus are specified in kilobaud (kBd). 1 kBd equals the trans-
fer of 1000 bits per second.
• With a transfer speed of 500 kBd sending a message needs approx. 0.3 ms.
• Every message is assigned a priority according to necessity and frequency of its occurrence
(importance). The priority is also assigned according to the "identifier". Messages are proc-
essed one after the other according to their priority.
How is the priority technically realized with the example of the drive control?
The cycle time, which is the time between the repeated transmissions of a message, depends
upon the importance and the frequency of modification of its contents. Important measured
values that change often must be sent to the bus at short intervals. The rpm must be read in
and processed by the drive control frequently. Therefore the message in which the rpm is sent
has a high priority.

5 Networking
TT_54_18_005701_SW
Binary value 1 is assigned to a subordi-

Recessive 3 Control unit 3 message
nate (recessive) priority.
Binary value 0 is assigned to a superordi- Message from control unit 1 has the
dominant 1 loses
nate (dominant) priority. binary value 1 and is thus recessive.
Message from control unit 3 has the
1 Control unit 1 message 3 loses
binary value 1 and is thus recessive.
2 Control unit 2 message
Result: Message from control unit 2 is superordinate and will therefore be processed first.
Transmission process
The CAN bus is designed with copper lines and operates with difference signals. These signals
are based on a fixed voltage value (picture 1 approx. 2.5 volts). The bus is theoretically de-
signed with 3 lines: CAN-HIGH, CAN-LOW, and CAN-GND (ground), although CAN-GND can also
be covered by the vehicle ground. CAN LOW has the complementary (mirror image) level of
CAN HIGH to ground. Thus, common mode interference and noise voltages (picture 2) can be
suppressed as the voltage difference (Δ) remains the same. In picture 2 the noise voltage is +1
V, which adds itself to the signal voltage. The difference signal Δ is still 2 V, however. The out-
put voltage of the signals (Picture 1 approx. 2.5 V) ensures system diagnosis if one or both CAN
lines are short-circuited to ground. The voltage value of the line to ground drops to zero. This is
recognized by the control unit and displayed as a fault. The ground connection is created inter-
nally. For this all control units are brought to a common voltage point. Perfect data transfer is
only guaranteed when both data lines function correctly. This requires perfect wiring.
Voltage value (picture 1) Common mode interferences and noise volt-
ages (picture 2)
TT_54_18_005702_SW TT_54_18_005703_SW
A CAN high A CAN high

B CAN low B CAN low

5 Networking
Single wire capability
The low-speed CAN is still able to function if there is a problem or defect with one line. The so-
called single-wire mode allows functions via one line in case of the following problems:
• Discontinuity in one of the two CAN lines
• Short circuit to ground or positive of a line
• Short circuit against each other
The precondition for single wire capability for the low speed CAN is a separate ground connec-
tion between the control units.
If both lines have a short circuit against U-batt or ground, no functions are possible!
CAN bus systems
Star and Terminal Points in Mercedes-Benz Trucks

The CAN networks are built with a linear structure with terminating resistors (between CAN
HIGH and CAN LOW). The terminating resistors are installed to prevent malfunctions, e.g. re-
flections. These are found in the star points or in control units. Star points that have no termi-
nating resistors and no ground connection are called terminal points. For purposes of differen-
tiation, star points have a black housing and terminal points have a white or yellow housing.
Ferrite elements are additionally integrated into both star points and terminal points. These
eliminate any voltage spikes that may occur.
Star point TT_54.10-006586-FA
Terminal point TT_54.10-006587-FA

5 Networking
Star and terminal points in the Actros 3

In Actros the star points are integrated in the base module: They form the interior CAN, frame
CAN, vehicle CAN, and telematics CAN. For the frame CAN the star point has been divided in
two for safety purposes. One star point connects the base module with the front module. The
second star point connects the base module with the rear module. If one of the CAN bus con-
nections fails, the connection can be maintained via the remaining star point. Network exten-
sions are done via external terminal points. In the ACTROS, these are Z2, Z3, and Z6.
TT_54_18_005704_FA
Limp-home concept for frame CAN

When the connection between the base module and front module or between the base module
and rear module in the frame CAN is disrupted, messages are transmitted by the base module
via the redundant CAN line between front module and rear module.
Frame CAN OK TT_54_18_006190_FA
Frame CAN discontinuity TT_54_18_006191_FA

5 Networking
When the connection between the base module and front module as well as between the base
module and rear module is disrupted in the frame CAN, messages are transmitted via the still
existing wake-up line in the form of PWM signals. The most important lighting functions are
therefore assured.
Diagnosis of CAN bus systems

There are various CAN BUS systems used in Mercedes-Benz trucks. They vary in the speed of K-
line, as well as of low-speed CAN and high-speed CAN. In order to clearly differentiate them,
they were given names corresponding with their tasks.
CAN bus systems
K-line U supply internal 24 V This is the data line with the lowest data speed, 9.6
U high ≈ 22.0 V kBaud. It serves as a connection between the vehicle
and the diagnostic socket, thus as the data line for the
U low ≈2V
off-board diagnosis.
U stroke 20.0V
Frame, vehicle, U supply internal 5 V There are two versions:
telematics, brakes, U high ≈ 3.5 V • The frame CAN, the telematics CAN and the SCR-
and SCR-CAN CAN with 250 kBaud each
U low ≈ 1.5 V
U stroke 2.0V • The vehicle CAN and the brakes CAN with 500
kBaud each
Tachograph CAN, U supply internal 5 V • TCO-CAN with 125 kBaud
body CAN PSM U high ≈ 3.5 V • Body CAN with 250 kBaud
U low ≈ 1.5 V
U stroke 2.0V
Interior CAN U supply internal 5 V 125 kBaud
U high ≈ 4.8 V
U low ≈ 0.3 V
U stroke 4.5V
Engine and trans- U supply 24 V U batt • 125 kBaud is used for the engine CAN.
mission CAN, U high ≈ 2/3 U batt • 250 kBaud is used for the transmission CAN.
Trailer CAN PSM U low ≈ 1/3 U batt
Trailer CAN BS U stroke 8.0V
Body CAN PSM
ASIC U supply internal 12 V 28.8 kBaud
U high ≈ 11 V
U low ≈ 0.1 V
U stroke 11V
LIN bus U supply 12 V 19.2 kBaud
U high ≥ 9.6 V
U low ≤ 2.4 V
U stroke 7.2V

5 Networking
LIN Bus (Local Interconnect Network)

The LIN bus is a sub-bus system that is connected to the CAN bus. The LIN bus is a single-wire
bus and operates with 19.2 kbit/s, making it twice as fast as the K-line. The internal power
supply is 12 V. The LIN bus requires a master and at least one slave. This is part of the base
module in the ACTROS 3. Up to 15 slaves (sensors) can be connected to it.
TT_54_00_005752_SW
1 Base module excerpt 3 Battery sensor excerpt
2 Rain/light sensor excerpt
There is a master unit (1), which always initiates the "activity". There are slave devices (2, 3),
which answer the master unit's queries. All slaves connected to the LIN bus can read the mes-
sage from the master and then decide whether the information is relevant for them based on
the ID and process the information correspondingly. The complete LIN bus traffic is initiated
and controlled by the master.

5 Networking
LIN bus - The tolerant bus

Transmitting Receiving
TT_00_19_005753_FA TT_00_19_005754_FA
The LIN bus is also known as the "tolerant bus".

This can be seen on both graphs:
When transmitting, "logical 1" is accepted, if at least 80 % of U (12 V) is applied to the LIN and
"logical 0", if < 20 % of U (12 V) is applied.
When receiving, "logical 1" is accepted, if at least 60 % of U (12 V) is applied and "logical 0", if <
40 % of U (12 V) is applied.

6 Practical Work 2
0 Instructions
6 Practical Work 2
Instructions
Overall duration .................................................................................................................15 min.
6.1 Networking
Further details on the Atego2, Axor2 and Actros networking
Exercises as individual work 13 min.


Presentation

6 Practical Work 2
6.1 Networking
6 Practical work 2 (Participants)

6.1 Networking
Exercise 6 Take a look at the networking in Actros3. Use the networking diagram to work through the
following exercises.
Fill in the missing information about the various data bus systems.
The baud rate at the frame CAN is…

250KB
The Lane Assistant SPA communicates with the
vehicle CAN via the component… Terminal point Z2
The transmission CAN connects the control
units… FR (CPC) to GS
The voltage swing of the CAN signal at the brake
CAN is approx. … 2V
For complete communication the engine CAN
requires … 4 twisted lines
The frame CAN communicates with the interior
CAN via the… Gateway in the base module
CAN9 fulfills the following tasks:
Flashing, quick test, telematics,
EOBD/SCR
Control unit flashing takes place via…
CAN 9
The components that communicate via the TCO
CAN are… Instrument and tachograph
The baud rate at the LIN bus is…
19.2 KB
The terminal point Z3 is part of the data bus…
CAN12 (SCR_CAN)
Exercise 7 Which control units are connected to the frame CAN bus?
Base module, front module, rear module, electronic air processing unit
(EAPU)
for SA BTS, ART2
Exercise 8 Identify all control units connected to the interior CAN bus.
GM, TMF, TMB, MSF, HZR, ZHE, SRS, INS, RAD

6 Practical Work 2
Exercise 9 What virtual control units are in the base module?
KOM, WS, EDW, ZDS
Exercise 10 The master function of the LIN bus network is located in which control unit?
Base module is master (and slave), RLS and IBS are slaves


7 Practical Work 3
0 Instructions
7 Practical Work 3
Instructions
Overall duration...............................................................................................................145 min.
7.1 Emergency Limp-home Concept in Actros3
The participants can apply the acquired theoretical content in practical situations.
Group 1 on emergency limp-home concept in Actros3
Group 2 on CAN measurement at model
Exercises at the vehicle / model 45 min
7.2 CAN Measurement on the Model
Group 2 on emergency limp-home concept in Actros3
Exercises at the vehicle / model 45 min

Training room/workshop 30 min.
Summary of 1st Day

Summarize what has been learned and discuss any open questions
25 min

7 Practical Work 3

Exercise 11 Interrupt the CAN connection from base module to front module, at plug X24 (BM). Which of
the functions listed can be performed by the front module? Check them off in the table.
Yes No
Left and right turn signal
X
Hazard warning flasher
X
Standing lamp and side-marker lamps
X
Low beams
X
High beams
X
Front fog lamps
X
Work lamp
X
Horn
X
Exercise 12 Describe the alternative path of communication with an interrupted CAN connection.
BM - HM - FM (redundant CAN is activated)
Exercise 13 How does the illumination respond to disrupted power supply to terminal 30 in the front mod-
ule?
Disconnect the battery. Remove the fuse for the front module in the power distributor. Recon-
nect the battery.
Note your observations of the following situations:

Standing lights activated
Front standing lamps and taillamp,
as well as side-marker lamps are
actuated
Low beams activated
Left low beam/standing lamps and
taillamp, as well as side-marker
lamps are actuated.

7 Practical Work 3
Low beams and hazard warning flasher activated

Low beam and taillamp, as well as
side-marker lamps are actuated.
When turning on the hazard warning
flasher, the left headlamp is turned
off.
The front and rear modules are supplied with voltage via the wake-up line. The power con-
sumption is limited to 8 A per module.
Exercise 14 How does the illumination respond to disrupted power supply to terminal 30 in the rear mod-
ule?
Disconnect the battery. Remove the fuse for the rear module in the power distributor. Recon-
nect the battery.
Note your observations of the following situations:

Standing lights activated
Front standing lamps and taillamp,
as well as side-marker lamps are
actuated
Additionally activate stop lamps and hazard warn-
ing flasher When turning on the stop lamps, the
hazard warning flasher is turned off.
Rear fog lamp activated
Rear fog lamp is turned off
Backup lamp activated
Backup lamp is turned off
The front and rear modules are supplied with voltage via the wake-up line. The power con-
sumption is limited to 8 A per module.

7 Practical Work 3

Exercise 15 The signals from the various data lines can be displayed with the oscilloscope.
Measure the various bus systems on the vehicle with the oscilloscope!
Frame CAN
Draw the signals into the picture and note the settings of the oscilloscope!
Oscilloscope TT_54_00_006603_FA
Measured volt-
age in volts:
CAN high High level
Low level
Exercise 16 Interior CAN

7 Practical Work 3
Measured volt-
age in volts:
CAN high High level
Low level

7 Practical Work 3
Exercise 17 LIN bus
Measured volt-
age in volts:
CAN high High level
Low level


8 Instrument
0 Instructions
8 Instrument
Instructions
Review of the 1st Day

Clarify unanswered questions from the 1st day, call-out questions

Presentation
8.1 Instrument
The participant can describe the features of the Instruments

Comparison of the two Instrument variants
8.2 Instrument 2004
The participant can differentiate between the two Instrument variants

The participant can perform practical work on the Instrument
Overview of Standard Instrument and High-Line Instrument
8.3 New ATEGO/AXOR Instrument
The participant can state the basic features of the new Instrument
Scope of modification of the INS 2004 compared with INS as of 12/2010
(New ATEGO/AXOR)

8 Instrument
0 Instructions
8.4 Instrument 2008
The participant can name the tasks of the INS 2008 and name the
main features of the INS 2008.
The participant can name the tasks and possible functions of the
sound module.
The participant can explain the tasks and how to handle the multifunction steering wheel.
The participant can understand how the multifunction steering wheel is operated.
The participant can name the distribution and settings of the driver information system.
Changes to the INS2008 compared to the INS2002
Sound module in the INS2008
Steering wheel buttons
Driver information system FIS
On-board diagnosis
Presentation

8 Instrument
8.1 Instrument
8.1 Instrument
The instrument cluster serves as the visual display unit for the driver.
The following instrument clusters are currently used in Mercedes-Benz trucks:

INS 2004 (Highline) in the Atego2 and Axor2 GT54_30_0241_C80 INS 2008 (High-Line) in the AC-
TROS3
TT_54.30-005763-FA
N_54.30-008684-SW
The instrument clusters have the following tasks in the vehicle:

In the ATEGO2/AXOR2
• Display of vehicle information for the driver
• Gateway between CAN bus systems, interface for diagnosis
• Manage the control units connected to the CAN network
In the ACTROS3
• Display of vehicle information for the driver
• Storage of the mirror memory
8.2 Instrument 2004

The Instrument 2004 is used with the introduction of the Global Cockpit in the
ATEGO2/AXOR2.
The aim is to offer a standardized instrument cluster for all ATEGO2/AXOR2 to meet all future
requirements.
Additional advantages are:

• Standardization of the control and display concept
• Improved readability of the display through reduction of the incoming light and avoiding light
reflections

8 Instrument
8.2 Instrument 2004
Standard Instrument High-Line Instrument
N_68.10-002256-SW N_54.30-008684-SW
There are 2 different versions:

• Standard Instrument (symbol display)
• High-Line Instrument (graphic-capable display, 2 LCD displays)
The Standard Instrument is used as standard equipment in the ATEGO2 and AXOR2R. The High-
Line Instrument is installed with one of the following special equipment variants:
• EV0 – communications interface
• EX3 – preinstallation for FLEETBOARD
• EM6 – brake control trailer integration
• EM8 – parameterizable special module
• ET8 – navigation unit
• JN6 – tachograph up to 140 km/h
In the AXOR2C, the High-Line Instrument is installed as standard equipment. Exception: Vehi-
cles produced in Turkey.
Standard Instrument
Standard Instrument
The Standard Instrument has a vehicle speed range of up
to 125 km/h. In one variant there is also a speed display
with a graduation in mph.
N_68.10-002256-SW
Special features:
• All standard and special equipment indicator lamps are located in a lower indicator lamp
bar.
• Expanded display functions in the newly developed multifunction display (MFD).

8 Instrument
8.2 Instrument 2004
• New display concept for operating and service information.

• All malfunction displays can be acknowledged in the Instrument.
• AdBlue fluid level display
• Operation via cross-shaped rocker switch in cockpit
• Integral trip computer (only with maintenance system WS)
• Information from the maintenance system can be displayed (only with WS)
• Integrated alarm
High-Line Instrument
High-line instrument cluster 2004
The High-Line Instrument has a vehicle speed range of up
to 125 km/h. In one variant there is a speed display with
a graduation in mph.
N_54.30-008684-SW
Special features:
• All standard and special equipment indicator lamps are located in a lower indicator lamp
bar.
• Displays in the large pointer instruments for outside temperature and odometer
• AdBlue fluid level display
• Operation via cross-shaped rocker switch in cockpit
• Integral trip computer (only with maintenance system WS)
• Information from the maintenance system can be displayed (only with WS)
• Integrated alarm
• Radio connection to the Instrument via the interior CAN
• Ecometer

8 Instrument

A modified Instrument will be implemented in the New ATEGO and New AXOR from 12/2010.
It is based on the Instrument 2004. The operating concept has remained unchanged.
TT_54_30_011149_FA
Design features
Chrome rings on 3D structure
Speedometer up to 120 km/h, optionally up to 140 km/h
Scopes of changes:
New ATEGO and New AXOR: The steering wheel buttons are connected directly to the instru-
ment cluster.
Departure check routine: When the ignition is switched on, the message "Departure Check" ap-
pears in the display for 2 seconds.
The system checks the following in sequence:
TT_54_30_011148_FA
• Oil level
• Coolant level
• Brake wear

8 Instrument
• Washer fluid level

• Air filter condition
• Condensation in the compressed air system
• Lights

8 Instrument
8.4 Instrument 2008
8.4 Instrument 2008

The Instrument 2008 is used in the ACTROS3. It is based on the Instrument 2002. The operat-
ing concept has remained unchanged.
Instrument 2008 TT_54_30_005763_FA
Design features
• Chrome rings on 3D structure
• Speedometer up to 120 km/h, optionally up to 140 km/h
• Variable green rpm range as thin band
• Green/yellow/red rpm range in the scale marker area
Scopes of changes
Rain/light Sensor
Green indicator lamps for low beams with rain/light sensor.

Trip computer
Determination of the range remains unchanged, the tank content indicator has been omitted,
however.
Control unit list in Diagnosis menu
The control unit list is designed in a ring structure.

Expansion of memory area:
The language area has been expanded. Up to four languages can be stored simultaneously.
Pressure indicator
The pressure display has been increased from 10 bar to 13 bar.

SR display for single tires
When the SR-off switch (stability control deactivated) has been activated, a red pop-up appears
"Stability control deactivated, speed max. 60km/h". This is only a message, which can be
acknowledged. The vehicle will not intervene in engine management.

8 Instrument
8.4 Instrument 2008
Sound Module in the Instrument

The sound module integrated in the Instrument generates different, context-related warning
and feedback sounds. The driver is given acoustic feedback via these tone sequences. Tone se-
quences can be triggered internally by the Instrument itself or by other control units. Triggering
the tone sequence via other control units is realized by the CAN bus.
Warning sounds
• Warning buzzer
• Light warning buzzer
• Acoustic warnings for ART and ABA
Feedback sounds
• Shift lever sounds
• Turn signal indicator sounds
• Button operation
The first coil of the dual coil speaker is used by the radio. The Instrument actuates the
second coil of the center speaker to acoustically produce the generated sounds.
TT_54_30_005764_SW
B28 Center speaker in roof X2 Instrument connector
X124.1 Driver footwell connector

The multifunction steering wheel allows the driver to operate and call up various systems (de-
pending upon the version). All functions of the multifunction steering wheel can be called up via
the menu item of the FIS (driver information system):

8 Instrument
8.4 Instrument 2008
Menu Operation
Check information For example, to call up the coolant temperature or the engine oil level
Audio For volume regulation or operation of the CD or cassette player
Maintenance To call up the calculated service date
Telephone To operate the telephone functions
Navigation To operate the navigation system
Trip computer To call up trip data
Preferences e.g. to set the time
Preferences To display the SMS messages (FLEETBOARD)
W_46_10_001009_FA
1 Function keys
Multifunction steering wheel networking

The function keys are connected to the base module.
The base module controls the following via CAN:

• the FIS in the Instrument
• the radio
• the telephone

8 Instrument
8.4 Instrument 2008
Multifunction steering wheel networking TT_46_10_005765_SW
Left multifunction steering wheel button

A7 Base module S144
group
A9 Radio S144s1 Scroll forward/back button
CAN1 Vehicle CAN S144s2 System selection button

Right multifunction steering wheel button
CAN2 Interior CAN S145
group
P2 Instrument S145s1 Buttons + and - for specific function
P2p1 Driver information system (FIS) display S145s2 Accept/terminate phone call button
Driver Information System (FIS) in Instrument

In the FIS the driver is shown information about the operating condition of the vehicle and
warnings. Diagnostic functions and settings for the display design are also available. The
graphic display is located in the center of the INS and is operated via the steering wheel but-
tons.
Basic display
The basic display of the FIS can be selected by the driver as:
• a black display
• a digital speedometer
• the current date
All displays except the gear indicator can be included or hidden.

8 Instrument
8.4 Instrument 2008
The multifunction display is subdivided into fixed sections.
N_54_30_008073_SW
Reminder field for fault displays; Only

1 User guidance 5 serious faults in the BS and TCO are
displayed using the system symbol.
Display window for locks, power take-off,
2 Selected basic display, e.g. speed display 6 leading and trailing axle and starting-off
aid
Display window for cruise control or ART
3 Level control 7
function
Gear indicator with splitter position and
4
display of the preselected gear
On-Board Diagnosis in Instrument

Event messages are displayed for the driver in the FIS. These are shown with a red or yellow
background, depending upon the severity of the event message. Directives (5) may be dis-
played in addition to a display with symbols and abbreviations. The event message can be ac-
knowledged by pressing the "FIS scroll forward/back" button. The event message is no longer
displayed in the FIS with this acknowledgment. The related symbol is still displayed in the lower
right-hand reminder field of the FIS (6).
"Display stress" is reduced by displaying only events relevant for the driver.
The events are ordered according to the following criteria:

• Legally required displays
• Display is relevant to safety
• Problem can lead to consequential damage

8 Instrument
8.4 Instrument 2008
N_54_30_008261_SW
5 Instructions for action
6 Reminder field for malfunction indications
An event message can be displayed in detail for on-board diagnosis. This is achieved using the
diagnosis menu:
1. Select "Settings" Confirm with "FIS scroll forward/back"

2. Select "Configuration" with "Plus/minus" button Confirm with "Arrow" button
3. Select "Enable diagnosis menu" with "Arrow" button Confirm with "FIS scroll forward"
4. Select "Diagnosis" with "Plus/minus" button Confirm with "Arrow" button

5. Select "Control unit abbreviated designation" with "Plus/minus" button Confirm with "Ar-
row" button
6. Select "Events" with "Plus/minus" button Confirm with "Arrow" button

After selecting "Events", the events for the respective control unit will be displayed. The control
units in the ACTROS use the hexadecimal system for fault type and fault path. Thus the events
are displayed in the Instrument in hexadecimal notation.
In this view the FIS provides the following information:
N_54_30_008111_SW

8 Instrument
8.4 Instrument 2008
Event severity from 0 to 2, where 2 has

1 Event number (e.g. E01) 3
the highest severity
Up-to-dateness "a" for current, no display
2 4 Event code in hexadecimal notation
for not current
The hexadecimal codes can be looked up in the Star Diagnosis simulation
Measurement and Binary Values in the Instrument

The on-board diagnosis system also provides current measurement values and binary values.
These values represent the current status (actual values) of control units and their inputs and
outputs. The following information is available for each control unit in the diagnosis menu:
Object number Binary values Measured values
TT_54_30_005768_SW TT_54_30_005769_SW TT_54_30_005770_SW
A Star Diagnosis simulation is required for a breakdown of the measurement and binary values:
• Control unit selection for simulation
• Using the front module (FM) as an example
• Press F6 in the front module menu
• In the front module help menu, select "Actual value numbering in DAS and in Instrument
display"

9 Practical Work 4
0 Instructions
9 Practical Work 4
Instructions
Overall duration................................................................................................................150 min
9.1 Driver Information System FIS in the Actros3
Group work in 3 groups
Group 1 on FIS in the Actros3
Group 2 on parameterization of INS in the Atego2/Axor2
Group 3 on steering wheel buttons at the model
Workshop 45 min
9.2 Parameterization of INS in the Atego2/Axor2
The participants can apply the acquired theoretical content in

practical situations.
The exercise is prepared with a 2004 instrument cluster.
For the new instrument cluster (as of 12/2010) various answers
may not be correct.
We recommend checking the answers with the participants
against the vehicle.
Workshop 45 min
9.3 Steering Wheel Buttons at the Model
Training room 45 min


9 Practical Work 4

Exercise 18 Describe the procedure to enable the diagnosis menu in Instrument 2008.
• Confirm selection "Settings" with the "FIS scroll forward/back."

• Select "Configuration" with "Plus/minus" button, Confirm with "Arrow"
button
• Select "Enable diagnosis menu" with "Arrow" button and confirm with
"FIS scroll forward."
Exercise 19 What information does the diagnosis menu show for the individual control units?
• Object number
• Measured values
• Binary values
• events
Exercise 20 Read out the binary value 01 from the FR control unit.
What four pieces of information does the binary value contain? Use the DAS simulation.
• BV01: 00 00 00 01
• From the right: 01: Terminal 15 actuated
• 00: Terminal 50
• 00: D+ input
• 00: D+ output
Exercise 21 Oil level of the engine. Work through the following 3 points. Take notes.
Read out the oil level.
Read out oil level "under "Check
information", monitoring info"
When does it makes sense to read out the oil
level? Engine off, engine oil warm, wait 1
min
Which control unit provides the value?
MR

9 Practical Work 4
Exercise 22 How is servicing confirmed in the WS?
• Show service message in display using buttons on the steering wheel

• Press reset button with pointed object
Exercise 23 What information can the driver call up in the menu "Trip computer"?
Range, driving and rest times
Exercise 24 What does the following fault code mean: 01329?
Name the fault priority rank, interpret the fault code.

Fault priority:
0 (is not shown in the display)
Fault code:
Overvoltage in the Instrument ter-
minal 30
Exercise 25 The GS back-up mode (emergency running mode) must be enabled on a customer vehicle.
How can the GS back-up mode menu be activated in the FIS via the steering wheel buttons?
Shift the gears available with the multifunction steering wheel!
• Go to menu item "Settings" in the FIS (scroll buttons)

• Select submenu "Configuration" (arrow keys)
• select "Enable GS back-up mode" and enable with + button
Exercise 26 What does the term "Towing" mean in the GS back-up mode menu?
In the "Tow" menu the range group is changed, in order to drive the oil
pump in the transmission when the engine is not running. (Observe opera-
tor's manual!!)

9 Practical Work 4

Exercise 27 Look at the following parameters of the 2004 Instrument (up to 12/2010).
Discuss the meanings of the given parameters in the group and make a note of them.
Speedometer menu
K factor
The K factor shows the number of
pulses of the speed sensor per
kilometer.
L factor
The L factor shows the wheel cir-
cumference in millimeters.
O factor
The O factor shows the number of
sensor pulses per wheel rotation.
When are these parameters used?
When the speed sensor is con-
nected directly to the Instrument
(special-purpose vehicle).
Trailer monitor menu
When are these parameters used?
When the semitrailer makes the
data available.
What parameters can be displayed?
Pressure, temperature and filling
capacities from the trailer supplied
via the PSM control unit and dis-
played.
Load standard equipment menu
What are the effects of this parameter?
The Instrument is reset to standard
parameterization (replacement part
status)!!!
Exercise 28 In which menu item of the DAS can the following parameterizations be performed?
Activate dumper indicator lamp
Menu item: Indicator lamps
Register PSM control unit when retrofitted
Menu item: Control unit list (CAN
bus control units)

9 Practical Work 4
Exercise 29 Which actual values in the instrument cluster can be used to check the following functions?
Note down the actual values.

Cross-shaped rocker switch
53, 54, 55, 56
Battery voltage
07
Reservoir pressure in brake circuit 2
02

9 Practical Work 4

Exercise 30 The steering wheel buttons are connected to the base module with 4 lines.
In the table enter the pin assignment at base module corresponding to the tasks.
Pin assignment Exercise
Steering wheel ground supply for background illumination.
X14 15/15
Background illumination for steering wheel buttons as PWM signal
X14 15/9
Signal line of the left steering wheel buttons (voltage supply of the right
X14 15/1 button group)
Signal line of the right steering wheel buttons (voltage supply of the left
X14 15/4 button group)
Exercise 31 Here you see the interior wiring diagram of the steering wheel buttons.
Assign the connections 1-4 in the picture to the tasks listed in the table.
TT_82.90-006325-SW
Connections Exercises
Steering wheel ground supply for background illumination.
3
Background illumination for steering wheel buttons as PWM signal
4
Signal line of the left steering wheel buttons and voltage supply of the right
1 button group
Signal line of the right steering wheel buttons and voltage supply of the left
2 button group

9 Practical Work 4
Exercise 32 Measure the voltage and the frequencies at the signal line for the left and right button groups
on the base module with the multimeter.
Actuate the buttons one after the other and note the values.
GM X14 15/1 GM X14 15/4
Left button group not Right button group not
actuated 16 V actuated 16 V
22.6 V 19.3 V
TT_46.10-006327-SW TT_46.10-006332-SW
23.5 V 21.3 V
TT_46.10-006329-SW TT_46.10-006333-SW
19.3 V 22.6 V
TT_46.10-006330-SW TT_46.10-006334-SW
21.3 V 23.5 V
TT_46.10-006331-SW TT_46.10-006335-SW
Frequency (Hz): Frequency (Hz):

XXX XXX


10 Base Module
0 Instructions
10 Base Module
Instructions
10.1 Base Modules
The participant can describe the features of the base module types
Brief comparison of the two base module types

Presentation
10.2 Atego2/Axor2 Base Module
The participant can name the major functions of the base module.
The participant can state the tasks of the relays.
Tasks and functions

Presentation
10.3 Base Module in Actros
The participant can name the major functions of the base module.
The participant can state the tasks of the relays.
The participant can name the different variants of the base module.
The participant can name the different functions of the base module.
Tasks and functions

Presentation
10.4 Central Data Memory / Mirror Memory
The participant can state the advantages and the design of the central data memory.
The participant can use the functions of the central data memory with the DAS.
Tasks and functions

Presentation

10 Base Module
10.1 Base Modules
10 Base Module (Participants)

10.1 Base Modules
In the Atego2/Axor2 and Actros2/3 different base modules are used:
Atego2/Axor2 base module Base module in Actros
TT_54_21_006589_FA
TT_54_21_006588_FA
Task: Task:
• Accommodates relays and fuses • Accommodates relays and fuses
• Distributes potential • Distributes potential
Functions: Functions:
• Accommodates the wipe-wash & turn signal • Central control unit in the networking
module • Information processing
• Exterior lamp failure monitor • Electronically secured load actuation

The same base module has been installed in the ATEGO2 and Axor2 as is used in the AXOR1
and in the ECONIC.
Atego/Axor base module
The tasks of the base module in the ATEGO2/AXOR2 comprise

• accommodating fuses and relays
• the voltage distribution

10 Base Module
Functions of the base module

The functions of the base module in the Atego2/Axor2 are differentiated according to external
and internal functions:
Functions External Internal
Wipe-wash, wiper control Wipe/wash/turn signal generator
(3+1; 3+2; 4+1; 4+2)
Intermittent wipe module Wipe/wash/turn signal generator
Turn signal generator Wipe/wash/turn signal generator
Hazard warning flasher relay Wipe/wash/turn signal generator
Hazard warning flasher relay Monitoring illumination on the tractor
vehicle
Design of the Atego2/Axor2 base module

Front view Rear view
W_54.21-001008-SW
TT_54.21-006590-SW
K1 Wipe/wash flasher relay

A1 Daytime running lamps relay
A2 Headlamp cleaning relay
K3 Additional headlamp relay
K4 Air drier heater
K5 D+ relay
K6 Stop lamp relay
K7 Backup lamp relay

10 Base Module
Location of relays, diodes, fuses

Additional fuses, relays and diodes can be installed in the Atego2/Axor2 via additional strips
next to the base module.
Fuse and relay box TT_54.15-006591-FA
A1, A2 Additional fuses A32 Additional relay (large)
A31 Additional relay (micro) D1-13 Diodes
Note
To protect the on-board electrical system, control units and consumers from induced volt-
ages, only additional relays with a freewheeling diode may be retrofitted.

10 Base Module

The base module GM of the Actros is located in the electrical compartment in the cab and is
accessible from the exterior and the interior. The GM is bolted to the frame of the cab/frame
separation point connector FF (cab/frame). All inputs and outputs from the cab of the vehicle
are received and transmitted here.
Front base module Rear base module with cab/frame separation point
connector
W_54.21-001269-SW
W_54.00-001153-SW
Important functions of the base module

EDW Theft warning system
KOM Provision of telematics data
WS Maintenance system
FFB Radio remote control
ZDS Central data memory
Exterior lights Actuation and monitoring
Interior illumination Actuation and monitoring
Windshield and headlamp cleaning Actuation and monitoring
Power take-offs Actuation and monitoring
Cab lock Monitoring
Trailer supply Power supply
Interface for body manufacturer Plug X7
Function pins Parameterizable functions saved
Turn signal indicators and hazard warning flashers Actuation and monitoring
LIN bus Actuation and monitoring

10 Base Module
Base module variants in the ACTROS

3 ex-factory base module variants are installed. The hardware varies depending upon the re-
quirements for each individual vehicle. The housings are identical, only the interior circuit
boards are equipped with different components. The control units shown are integrated accord-
ing to the variant.
Maximum GM variant TT_54_20_006592_SW
Note
Only the maximum base module version is available from the Mercedes-Benz parts service
as a replacement part!
Modifications to the base module in the ACTROS

• Base modules can be flashed with the SDflash release CD from release 1 to release version
2 (software release 5.12)
• As of 10/2005, an advance development is introduced into the series production with soft-
ware release 5.34. This is designated release 2c
• As of 12/2006 introduction of software release 5.53/5.54. This is designated release 2d.
• As of 10/2007 introduction of software release 6.4. This is designated release 3.
Additional applications for BM Release 3:
Software modifications: Hardware modifications:
• LIN bus interface functionality for rain/light sensor • Connection of interior sensor to the anti-theft alarm
and battery sensor system in the base module
• Wig-wag lights function • LIN bus interface for rain/light sensor (RLS)
• (Daytime running lights shutoff with engaged power • (LIN bus interface for battery sensor (IBS))
take-off)
• Actuation and monitoring of LED turn signal lamps in
the trailer
• CDM optimization
• Increased driver performance for sliding/tilting roof
and tilting roof relay actuation
Additional applications for GM Release 3b:

Software modifications: Hardware modifications:
• Monitoring of the on-board electrical system (note to No changes.
the driver in INS about the battery condition)

10 Base Module

The base module has a central data memory, where all parameters for the control units fitted in
the vehicle are stored. The central data memory continuously keeps data ready for the control
units. When needed, e.g. exchanged control unit, the parameters are transferred to the new
control unit from the central data memory.
The following data is stored in the central data memory for each control unit:
• MB object number
• Hardware and software versions
• Diagnosis version
• Diagnostic data
• Date of the last control unit lock
• Parameter data
• History data for WS
When terminal 15 is switched on, the date of the last parameter change in the control units is
checked and compared with the CDM. When parameter or control unit versions are changed,
the CDM must be updated with the diagnosis device. For safety purposes parts of the CDM
data are stored in the Instrument mirror memory. This makes it possible to replace the base
module and recover important BM data (from CDM to BM).
Note
Data from the MR and TCO control units is not stored in the CDM for safety reasons.
When replacing a control unit with different diagnosis versions on a trial basis, make sure
that the CDM is only updated after the final control unit replacement.
Mirror memory
To backup base module data, the parameters of the BM and vehicle maintenance data as well
as parts of the CDM data are stored in the mirror memory. When needed, e.g. for a base mod-
ule replacement, the parameters can be transferred to the new control unit from the mirror
memory. The mirror memory is located in the Instrument.
The following data are stored in the mirror memory:

• Control unit list
• History data for WS
• BM parameter data
• BM hardware and software versions
• BM diagnosis version
• Diagnostic data
• Date of the last control unit lock

10 Base Module
When terminal 15 is switched on, the contents of the CDM and BM data are compared with the
mirror memory. If there are changes in the parameters or the control unit list, the CDM or mir-
ror memory must be updated with the diagnostic unit.

11 Practical Work 5
0 Instructions
11 Practical Work 5
Instructions
11.1 Signal path
Exercises as individual work in the 60 min.

training room

15 min.

11 Practical Work 5
11.1 Signal Path

11.1 Signal Path
Exercise 33 Sensors, switches and consumers are connected to the control units.
Mark the control unit in the table to which the listed components are connected. Use the cir-
cuit diagram.
Component FM GM HM
Front axle position sensor for level control
X
Rear axle position sensor for level control
X
Condensation sensor
X
Brake wear sensor
X X
Parking brake switch
X
Ambient temperature sensor
X
Rear axle temperature
X
Wiper motor for windshield
X
Auxiliary high beam
X
Taillamp
X
Side-marker lamps
X X
Horn
X
Roof air horn solenoid valve
X
Differential lock solenoid valve, front axle
X
Differential lock indicator switch, front
axle X
Differential lock solenoid valve, rear axle
X
Differential lock indicator switch, rear axle
X
Air drier heater
X
Cab lock
X
Indicator switch for steering oil level
X
Fuel tank sensor
X

11 Practical Work 5
11.1 Signal Path
Exercise 34 Answer the questions on illumination in the ACTROS3.
Use the workshop literature and circuit diagram.
Note the control unit designations to which the listed lamps are connected.
TT_82.10-006341-SW
Lamp Designation
Low beams
FM
Rear fog lamp
HM
Clearance lamps in the roof
GM
Front fog lamps
FM
Illumination for trailer
GM

11 Practical Work 5
11.1 Signal Path
Exercise 35 Look at other illumination actuations in the ACTROS3.
What is the signal path for the stop lamp actuation with BS2?
TT_82.10-006338-SW
From the BS control unit via the vehicle CAN to the base module (GM)
From the GM to the HM rear module and to the trailer socket
Exercise 36 Look at other illumination actuations in the ACTROS3.

What is the signal path for the backup lamp actuation for GS?
TT_82.10-006340-SW

11 Practical Work 5
11.1 Signal Path
From shift control unit at the drive control, From the drive control via
transmission CAN to BS.
From GS via transmission CAN to FR via vehicle CAN to GM, from there to
HM and to the trailer socket
Exercise 37 Discuss the signal path to actuate the brake lights on the Axor2.
Draw the path into the picture below.
TT_82_10_006342_SW
Brake value sensor - BS - FR - GM - FF – backup lamps/ trailer so-

cket(brake light relay GM)

11 Practical Work 5
Exercise 38 Discuss the signal path to actuate the backup lamp on the Atego2 with AGS2.
Draw the path into the picture below.
TT_82_10_006343_SW
Shift control unit – FR – AGS2 – FR – BM (RFS relay) – FF cab/chassis

separation point – trailer socket/backup lamp


12 Trailer Socket
0 Instructions
12 Trailer Socket
Instructions
Total time ..........................................................................................................................70 min.
12.1 Trailer Socket
The participant can explain the connection of the trailer socket in the vehicle.
The participant can name the maximum power consumption of the trailer lighting.
Pin assignment and current load
12.2 Cotel Interface
The participant can describe the task of the CoTel interface.

Cotel task
12.3 Modular Switch Panel (MSF)
The participant can describe the design and the tasks of the modular switch panel.
The participant can name the main features of the modular switch panel.
The participant can name the parts and components of the modular switch panel.
The participant can state the special features in reference to retrofitting.
General description of the modular switch panel
Master, slave, load, and signal switch
40 min.
Summary of 2nd Day

Clarify unanswered questions from the 2nd day, call-out questions

Presentation

12 Trailer Socket
12.1 Trailer Socket
12 Trailer Socket (Participants)

12.1 Trailer Socket
The trailer socket is supplied by the base module.
Trailer recognition
The trailer recognition takes place via the backup lamp, left turn signal indicator and right turn
signal indicator outputs. Trailer recognition is conducted via the quiescent current consumption
with an active terminal 15. If the base module registers a closed circuit on one of these out-
puts, the trailer is considered recognized.
Electronic protection of the outputs
To protect the outputs the load current is measured on the connection pin. If the load current
exceeds the specified limit of approx. 20 ms, the connection is deactivated (electronic protec-
tion). By activating/deactivating terminal 15 or the consumers, the load current is measured
again. The stop lamp of the trailer is protected by a fuse in the base module and has no elec-
tronic protection.
Turn signal indicator bulb failure recognition
A current measurement is conducted during the first left and right turn signal indicator opera-
tion after trailer recognition ("Trailer present"). The power consumption of the two sides is
compared. After the next turn signal indicator operation, a difference is evaluated as the failure
of a bulb and displayed as a defect. The turn signal frequency is doubled.
LEDs on the trailer
As of base module Release 3, LED turn signal lamps in the trailer can be checked for function
and failures by the base module. When the trailer is connected, the lamp failure recognition be-
comes active and determines whether LEDs in the trailer turn signal lamps are installed via the
test current and a measurement circuit.
Current load of the 15-pin trailer socket

Designation Pin Release 1 Release Release
2/SW5.12 3/SW6.4
Left turn signal external relay 1 2x lamp pattern 3x lamp pattern 4x lamp pattern
Right turn signal external relay 2
Rear fog lamp, external relay 3
Tml. 31 4
Left standing lamp trailer socket terminal 58 L 5
Left taillamp
Left clearance lamps
Left license plate lamp
Left side-marker lamp
External relay

12 Trailer Socket
12.1 Trailer Socket
Designation Pin Release 1 Release Release

2/SW5.12 3/SW6.4
Right standing light trailer socket terminal 58 R 6
Right taillamp
Right clearance lamps
Right license plate lamp
Right side-marker lamp
External relay
Terminal 54 stop lamp 7
Backup lamp, external relay 8
Terminal 30 9 Max 10A
Reserve 1.5 mm² 10 FF5.1 18/5
Reserve 1.5 mm² 11 FF5.1 18/6
Reserve 1.5 mm² 12 FF5.1 18/7
Tml. 31 13 Max 10A
Trailer CAN bus, CAN high 14 To the PSM
Trailer CAN bus, CAN low 15 To the PSM
Note
Output is switched off with increased power consumption.

12 Trailer Socket

Various preinstallation and equipment variants for telematics systems are offered ex factory:
Code EH7
The COTEL telematics interface is a standardized interface for fleet management systems from
different manufacturers. The interface converts the vehicle-internal CAN data into the standard-
ized SAE J1939 format and forwards it to the fleet management system. The data contents of
the interface are defined and agreed upon by the following manufacturers: Daimler, DAF,
IVECO, MAN, Scania and Volvo. As such, different fleet management systems may use the ob-
tained vehicle data without problem and independent of manufacturer brands. The data output
takes place using the base module GM or via the parameterizable special module PSM. De-
pending on vehicle design, the following data (maximally) may be retrieved:
Cotel data
• Stop lamp switch
• Vehicle speed (wheel speed)
• Cruise control status
• Clutch status
• Power take-off status
• Accelerator pedal position
• Total fuel consumption
• Fill level of fuel tank
• Engine rpm
• Axle load of individual axles
• Total vehicle weight
• Total engine operating hours
• Vehicle identification number
• Software identification number
• Total mileage of vehicle (km)
• Next scheduled maintenance service
• Tachograph information
• Vehicle speed (tachograph)
• Engine coolant temperature

12 Trailer Socket

The ergonomics for the driver have been improved by the design of the switch panel. The
switches with important functions to perform while driving have been combined in easy-to-
reach modules. Additional switch panels are located in the headliner above the driver area and
in the side wall.
Advantages of the modular switch panel:

• Fewer lines and connectors
• Fewer cable sets and less weight
• Installation space and routing radius optimized
• Improved individual adaptation
• Simpler retrofitting
Modular switch panel TT_54_25_005660_FA

12 Trailer Socket
Modular switch panel networking
W_54_25_001022_SW
1 ASIC bus A77 Dash support switch module
10 Driver dash support area A78 Dash support switch module
11 Center dash support area A79 Dash support switch module
12 Left dash support area A80 Dash support switch module
13 Roof area A81 Dash support switch module
14 Rear panel area A82 Lock switch module
A7 Base module A83 Roof switch module
A68 Master switch module A84 Rear panel switch module
A69 Dash support switch module CAN 2 Interior CAN
A70 Rear panel switch module S24 Exterior light switch
A71 Dash support switch module S25 Pitman arm
A76 Dash support switch module S26 Headlamp range adjustment
ASIC sub-bus
The modular switch panel consists of a master module (A68) connected to the interior CAN
bus. The hazard warning flasher switch is integrated in the master module. Two signal switches
left and right from the hazard warning flasher switch can be inserted into the master module.
Several slave modules (switch modules 1-12) are connected to the master module. Additional
switches can be accommodated in these.
The plug-in single switches can be pure signal switches. Their switch information is transmit-
ted via the ASIC data bus (ASIC = Application System Integrated Circuit) as a data telegram to
the master. The ASIC data bus operates at approx. 30 kBaud. The master module transmits the
information to all other components in the vehicle via the interior CAN.

12 Trailer Socket
The following is transmitted in the data telegram:

• Switch identification
• Switch position (only signal switches)
• Actuation of the switch illumination
• Actuation of the indicator lamp in the switch
There are also load switches that can energize consumers directly. These load switches are
also connected to the ASIC data bus. The master recognizes the existence of these switches
and actuates the background illumination of the switch.
A slave module has four plug positions in which signal or load switches can be inserted. The
load to be switched in load switches can be connected to the switch on the back of the slave
control panel in the provided openings.
Components
Master module
Function:
• Read in switch signals from all connected components
• Read in messages from all signal switches
• Accommodate 2 signal switches
• Integral hazard warning flasher switch
• Transmission of switch signals to base module
• Actuate switch illumination
• Monitor switch
Master module TT_54_25_005771_FA
Slave module
Function:
• Accommodate max. 4 signal or load switches
• Interface between signal/load switches and the master module

12 Trailer Socket
Slave module TT_54_25_005772_FA
Signal switch
Signal switches send a data telegram after actuation or on request to the modular switch panel
via the ASIC data bus. This is how they digitally transmit the respective switch request to the
master switch panel. Every switch sends its own data telegram and has a fixed assigned func-
tion. It thus has its own identity and part number.
Function:
• Transmit its own switch identification via the ASIC data bus
• Transmit switch information to the ASIC data bus
• Pick up information via the ASIC data bus
• Actuate the indicator lamp in the switch
Signal switch TT_54_25_005663_FA
Special feature:
Individual functions, e.g. the interior lamp, can be activated from the driver seat or the bunk. To
avoid problems, no switches with the same part number may be installed more than once in the
MSF!

12 Trailer Socket
Load switch
Load switches have additional load pins in addition to the pins for connecting to the ASIC data
bus to perform their respective functions directly via the switch.
Function:
• Transmit its own switch identification via the ASIC data bus
• Switch consumers directly via conventional load pins
• Pick up information via the ASIC data bus
• Actuate the indicator lamp in the switch
Load switch TT_54_25_005664_FA
Load pins:
• Switch the respective function directly, max. load 5 A
Pitman arm
The pitman arm is connected to the master module. Switch signals of the pitman arm are read
in by the master module, monitored, and transmitted via CAN to the base module.
Functions:
• Left/right turn signal
• Low beams/high beams
• Headlight flasher
• 3-stage wiper: Intermittent wipe, window wipe/wash, touch wiping
• Horn
• Switch position is reported to the MSF

12 Trailer Socket
Pitman arm N_82_30_002039_SW
Exterior lamp switch
The position of the rotary light switch is read in by the master module via microswitches and
thus the respective switch position is recognized. The switch is monitored and interpreted by
the modular switch panel and the switch position is transmitted to the base module.
Functions:
• Automatic (light sensor function)
• Standing lights
• Low beams
• Front fog lamps
• Rear fog lamp
Rotary light switch TT_54_25_005665_FA
Note
The rotary light switch and the pitman arm must not be placed under load by additional
consumers!
Headlamp range adjustment HRA [LWR] in vehicles with steel suspension
The position desired by the driver on the headlamp range adjustment switch is evaluated in the
master module. The resistance value is interpreted in the master module and transmitted as a

12 Trailer Socket
CAN signal to the front module via the base module. The front module actuates the motors of
the headlamp range adjustment in the headlamps accordingly.
Headlamp range adjustment N_54_25_002438_SW
Differential lock switch
Different rotary switches are used depending upon the vehicle equipment.
Functions of the right switch:

• Inter-axle lock
• Rear axle interaxle differential lock/differential lock
• Rear axle and front axle interaxle differential lock/differential lock
Functions of the left switch:
• On and off-road gear
The switch position is recognized via different resistance values in the rotary switch. The mas-
ter module evaluates this information and transmits a CAN signal via the base module to the
front module.
Differential lock switch TT_54_25_005666_FA

13 Practical Work 6
0 Instructions
13 Practical Work 6
Instructions
Review of 2nd day


Presentation
13.1 Modular Switch Panel
The participant can understand the retrofitting of switches in the modular switch panel.
The participant can perform practical operations on the modular switch panel.
The participant can perform a proper diagnosis at the modular switch panel.
Exercises as individual work in the 10 min
training room

13 Practical Work 6
13.1 Modular switch panel

Exercise 39 Designate the signal form to transmit the switch position of the light switch to the master
module.
Mark the correct answer with an "X".
Answer
Discrete cabling
X
ASIC data bus
Coded resistance
Exercise 40 What information is transmitted from the master of the modular switch panel to the switches?
Signal switch: Background illumination, actuation of the indicator lamp

Load switch: Background illumination
Exercise 41 Which data buses are connected to the master of the modular switch panel?
Interior CAN, ASIC data bus
Exercise 42 Designate the signal form to transmit the switch position of the lock switch to the master
module.
Mark the correct answer with an "X".

Answer
Discrete cabling
ASIC data bus
Coded resistance
X
Exercise 43 How high is the baud rate at the ASIC data bus?
approx. 30 kBaud

13 Practical Work 6
Exercise 44 All slave modules are connected through 3 lines via the ASIC sub-bus system with the master
module. Find out which pins are used for power supply and which pin is used as data line.
Also write down the colors of the lines!

X1 3/1
Voltage supply 24 V blue
X1 3/2
Data line brown/red
X1 3/3
Ground yellow
Exercise 45 When there is a problem in the modular switch panel, an integral safety concept is applied.
What does the illumination of the vehicle do when there is a problem in the MSF system?
Note down the result.
a) Remove plug X3 to the light switch from the master module. Turn the ignition on.
Standing, low beam and taillamps as well as the side-marker lamps are
autom. actuated.
b) Remove plug X3 to the light switch on the master module and turn the ignition on. Actuate the
left and right turn signal.
Turn signals are actuated
Exercise 46 What does the illumination of the vehicle do when there is a problem in the MSF system?
Note down the result.
a) Remove plug X1 to the base module from the master module. Turn the ignition on.
Standing, low beam and taillamps as well as the side-marker lamps are
autom. actuated.
b) Remove plug X1 to the base module from the master module. Turn the ignition on. Actuate the
left and right turn signal.
Turn signal are not actuated.

14 Exterior Lighting
0 Instructions
Instructions
14.1 Exterior Lights on the ATEGO2 / AXOR2
The participant can understand the actuation of the exterior lights.

The participant can describe the modifications of the main headlamps.
Headlamps and repairs
5 min.
14.2 Actros Exterior Lights
The participant can describe the design of the main headlamps.

The participant can describe the design and method of operation of the xenon headlamps.
The participant can state the design and the operation of the gas discharge lamp.
The participant can state the safety regulations and precautions for xenon headlamps.
Exterior lights: H7 and xenon

14.1 Exterior Lights on the ATEGO2/AXOR2
14 Exterior Lights (Participants)

The H1 high beam and H7 low beam are generated separately in the clear glass headlamps, al-
lowing activation of the high and low beams simultaneously, so that significantly more light is
available at the light-dark boundary.
ATEGO2
The turn signal lamp is located above the bumper.
For the ATEGO2 the H1 high beam, H7 low beam
and H1 fog lamps are integrated into the head-
lamps.
N_82_10_002449_FA
Information
Due to the high light output of the high beam, European Union legislation has stipulated
that in the vehicles ATEGO2 and AXOR2 no additional high beam headlamps may be oper-
ated. No additional high beam headlamps are available ex factory.
Axor2C
For the AXOR2R and AXOR2C the turn signal
lamp, H7 low beam and H1 high beam are inte-
grated into the headlamp housing. If a front fog
lamp is installed, it is located below the main
headlamp in the bumper.
N_82_10_002453_FA
Repair tip
The clear glass lenses of the headlamps can be replaced in the ATEGO2 and AXOR2. To
remove the headlamp trim in the AXOR2R and AXOR2C the mounting screw 1 must be
removed. Then the two mounting screws 6 of the headlamp can be removed. Swivel head-
lamp out approx 10 cm, remove turn signal lamp cable set and remove turn signal lamp.
The headlamp can now be completely swiveled out.
AXOR2

N82.10-2399-31 N_82_10_002399_FA
N82.10-2400-31 N_82_10_002400_FA
1 Mounting screw
2 Panel 5 Adjusting screw
Headlamp mounting
3 Turn signal lamp 6
screw
4 Headlamps
The Axor2C is also available with xenon headlamps (code LG1).

14.2 Exterior Lights on the ACTROS

In the Actros two types of headlamps can be installed:
• Halogen headlamp, code L12
• Bi-xenon headlamp, code LG0
In contrast to the Actros 2, no holes for adjusting in the bumper can be seen. The chrome
molding must be unscrewed for this purpose.
Actros 3 TT_82_10_005775_FA
Note
Due to the high light output of the high beams, European Union legislation stipulates that
no additional high beam headlamps be operated in the ACTROS. No additional high beam
headlamps are available ex factory.
Bi-xenon headlamps
Design
Bi-xenon headlamp TT_82_10_005776_FA
1 Turn signal lamp 3 Standing lights
2 Headlamp flasher/high beam 4 Low beam/high beam (bi-xenon)

Lens TT_82_10_005777_FA
5 Position of the blind for high beam
6 Position of the blind for low beam
A bi-xenon headlamp fills two functions with a single lamp:
Low and high beam.
The use of a movable blind in the headlamp allows electromagnetic switching between the low
beams and high beams. When switching to high beams the coil is energized and attracts an iron
core. The iron core is mechanically connected with the blind. The blind is swiveled up and down
via a linkage.
Safety note
Risk of death. High voltage at Xenon headlamps may result in death.
Safety regulations for handling Xenon headlamps:
WIS: AS82.10-Z-0001-01A
Risk of death
Xenon headlamps operate at a dangerous output range. Due to the high voltage, contact
with electrically conducting parts can be deadly! Electric shocks can cause fibrillation of
the heart or even cardiac arrest. The effects of an electric shock may sometimes first ap-
pear after several minutes; for this reason always consult a physician.
Safety instructions/precautions
• Persons with electronic implants (e.g. pacemakers) should never work on xenon head-
lamps.
• Before working on Xenon headlamps (e.g. when replacing parts, connecting testers,
etc.) turn off lights.
• Never come into contact with parts conducting high voltage when xenon headlamps
are on.

• Wear safety shoes (with rubber soles).
Xenon headlamp operation

When the low beam is switched on, the control unit activates the ignition module within a few
milliseconds with the control voltage. A high voltage surge of approx. 20 kV from the ignition
unit creates an arc of light between the electrodes thus igniting xenon lamp. If an arc of light
with sufficient stability is recognized the control electronics switch to limited power mode. The
electrical power output is regulated to 35 W. A voltage converter generates the voltage of
approx. 85 V required for the xenon lamp to function safely.
Electrical ballast and ignition module with xenon bulb TT_82_10_005778_FA
Headlamp cleaning system

Particles of dirt on the surface of the headlamp diffusion plate deflect light rays and dazzle on-
coming traffic. With xenon headlamps, this dazzle effect is very high due to the high light inten-
sity. This is why headlamp cleaning systems are legally required for headlamp systems with gas
discharge lamps.
The nozzles are installed in a telescope arm above the lamp unit. The headlamp cleaning sys-
tem is activated via a separate switch.
TT_82_10_006622_FA
Gas discharge lamps

The burn chamber of the xenon lamp is filled with xenon and a mixture of metal-halogen salts.
This mixture is ignited by high voltage. The color of the light is similar to daylight. Xenon lamps
have a timed warm-up, which is technically determined. After being turned on, 50% brightness
is reached within 1 to 2 seconds and the full brightness after 30 seconds.

Xenon gas discharge lamp TT_82_10_005780_FA
The light output in comparison:
TT_82_00_005781_FA
Fig. on left Halogen low beam (H7)

Fig. on
Xenon light
right

15 Exterior Lamp Failure Monitor
0 Instructions

Instructions
15.1 Bulb Failure Monitor in the Atego2/Axor2
The participant can describe the functioning of the bulb failure monitor.
Voltage divider, Ohm's law, necessity of operation amplifier
10 min
15.2 Bulb Failure Monitor in the Actros
The participant can describe the functioning of the bulb failure monitor.
Description of the bulb failure detection, static/dynamic
Voltage divider, Ohm's law, necessity of operation amplifier
Presentation

15 Bulb Failure Monitor (Participants)

How does the Bulb Failure Monitor (GLK) function?
When the circuit is closed, a specified current flows through the bulbs via resistor R . This
causes a voltage drop UR at resistor R which is measured by the OP amplifier. When the current
changes (e.g. bulb failure) the voltage drop at resistor R also changes. This is detected by the
micro-controller (μC) and transmitted as a fault message to the INS via the "bulb failure indica-
tor" line.
How is a fuse monitored by the GLK?
The fuses are monitored by the μ-controller via a logic circuit. This compares the voltage
statuses of two lines:
• Reference line from fuse input to the μ-controller.
• OP amplifier output to the μ-controller.
E.g. Standing lights:
If voltage is present at the input of the fuse then the corresponding current must flow via resis-
tor R
E.g. stop lamp:

If a signal from the FR is present at the stop lamp relay tml. 86 then current must also flow on
the output tml. 87.
This circuit monitors both fuses and bulbs.
The following lamps are monitored through the bulb failure monitor in the base module of the
Atego2 / Axor2:
Component
Right/left taillights monitored
Right/left standing lights monitored
Turn signal lamps not monitored
License plate lamp monitored
Right/left high beams not monitored
Backup lamp not monitored
Right/left low beams monitored
Brake lights monitored
Rear fog lamp monitored


In the Actros the bulbs of the exterior lights are monitored. The monitoring is performed by the
corresponding control units. They include the base module for the trailer monitor, the front
module for the front lighting devices and the rear module for the rear lighting devices. Depend-
ing on the software version, the lamps are (statically) monitored when the lights are switched
off or (dynamically) monitored when the lights are switched on.
At the rear module before Release 3 the bulb failure monitoring occurs (statically) when the
lights are switched off. A test current flows via a voltage divider in the control unit over the
glow coil of the bulbs. The voltage drop created is evaluated by the electronics.
Function before Release3:

If there is a discontinuity in the current path a higher voltage will be measured on the voltage
divider. This is detected by the micro-controller (µC), evaluated, and sent as an error message
via CAN to the INS.
Rear module before Release3 TT_54_20_005782_SW
In the rear module as of Release 3 (as of 12/2006) extended bulb monitoring takes place (dy-
namically) via comparison of power consumption. The advantage is that the bulbs are also
monitored when the illumination is switched on (daytime running lights).
The extended functions as of Release 3:
The rear module compares the power consumption of the left and right consumer. The meas-
urement takes place via the voltage loss recorded by the operation amplifier (OP). This value is
reported to the micro-controller.
Rear module as of Release3 TT_54_20_005783_SW
The following table shows the bulb failure monitoring system of the Actros with base module re-
lease 3 and rear module release 3:

Front module Static Dynamic

Left front fog lamp X
Right front fog lamp X
Left turn signal light X X
Right turn signal light X X
Left standing light X
Right standing light X
Left low beam X
Right low beam X
Left high beam X
Right high beam X
Left side marker lamps
Right side marker lamps
LI perimeter lamp
RE perimeter lamp
Rear module Static Dynamic

Left side marker lamps X X
Right side marker lamps X X
Left taillight X X
Right taillight X X
Left brake light X X
Right brake light X X
Left backup lamp X X
Right backup lamp X X
Left turn signal light X X
Right turn signal light X X
Rear fog lamp X
License plate lamp X
Base Module Static Dynamic

LI perimeter lamp X
RE perimeter lamp X

16 Practical work 7
0 Instructions
16 Practical work 7
Instructions
Total time ...........................................................................................................................20 min
16.1 Possibilities of Fault Detection by Control Units
The participant can describe the fault detection by control units.

Possibilities of fault detection by control units
20 min.

16 Practical work 7

Exercise 47 Which faults can a control unit recognize in particular? The options for Star Diagnosis are listed
in the picture. To answer this question, take a look at various wiring variants used in practice.
Consider the variants shown and decide which of the faults listed could be recognized by the
control unit.
TT_54.00-006346-SW
1 Open circuit 3 Short circuit to positive
2 Short circuit to negative 4 Line short circuit
Place an X next to the fault that Star Diagnosis detects.

1
TT_54.00-006348-S
TT_54.00-006347-SW

16 Practical work 7
a) Explain your statement according to the voltage divider principle.
Interruption: The voltage to the microprocessor increases, since no cur-

rent flows through the voltage divider and therefore no voltage drop oc-
curs at the resistors.
Exercise 48 Place an X next to the fault that Star Diagnosis detects.
TT_54_00_006349_S
TT_54_00_006347_SW
Short circuit to positive. The voltage to the microprocessor is excessive,

since the battery voltage is applied at the voltage divider.

16 Practical work 7
GT54_00_0271_C81 in M04 TT_54_00_006350_S
TT_54_00_006347_SW
Short circuit to ground: The voltage (feedback) to the microprocessor

drops below the expected voltage value.

16 Practical work 7
TT_54_00_006351_S
TT_54_00_006347_SW
Short circuit to positive. The voltage (feedback) to the micro-processor is

greater than expected.
TT_54_00_006352_S
TT_54_00_006347_SW

16 Practical work 7
Is not recognized: The open circuit has the same effect as an open
switch.
TT_54_00_006353_S
TT_54_00_006347_SW
Short circuit to positive. The voltage to the microprocessor is excessive,

since the battery voltage is applied at the voltage divider.

17 Door Module
0 Instructions
17 Door Module
Instructions
Total time ...........................................................................................................................20 min
17.1 Door Control Panel in ATEGO2/AXOR2
The participant can name the design and function of the controls in the doors.
Door control panel
17.2 Door Module for ACTROS
The participant can describe the design and function of the controls in
the doors.
The participant can describe installation locations, tasks and functions of the door
modules.
The participant can describe the theoretical operation of the switch units
in the doors.
General description and variants

17 Door Module
17 Door Module (Participants)

Tasks of the door control panel
Different control panels are used for driver/passenger side depending on equipment installed
(central locking, comfort locking system). The actuation of door components takes place via the
door control panel.
Door control panel TT_72_40_006656_FA
The components on the circuit board of the door control panel have the following tasks:
• Switch illumination LED
• Transistors to relieve the switching contacts for the functions of power window, mirror ad-
justment, mirror heater and CL actuators
Note
When working on door control panels, the maximum power consumption of the power
window (25A), mirror heater (7A) and mirror adjustment (1A) must not be exceeded. Cor-
rect polarity of the connections must also be observed (no polarity protection).

17 Door Module
17.2 Door Module in Actros

The door consists of an outer module and an inner module, which can be separated from one
another. The door operation from the outside is the same as in the Actros 2. The cold or hot air
is supplied to the side windows by an added air distributor. The integrated door control unit in-
stalled underneath the trim forms the interface to the interior CAN. The following functions or
partial functions are controlled via the door control unit:
• Buttons of the door control panel
• Interior lights actuation
• Entrance lamp
• Anti-theft alarm system (EDW) special equipment
• Comfort locking system (KSA) special equipment
• Mirror heater/mirror adjustment
Door module W_72_29_001011_SW
1 Door trim inner section
A66 Driver door module (TMF) control unit
The following door control units are used in the ACTROS:

• Driver door module TMF (A66)
The driver door module control unit controls the functions in the driver door area.
• Passenger door module TMB (A67, without picture)
The passenger door module control unit controls the functions in the front passenger door
area.
To reduce wiring and connectors to the doors, all functions are actuated and monitored via the
door control unit. Information between the control units in the driver and passenger doors is
exchanged via the interior CAN bus.
There are two variants with different functions:
Base-Line
• Driver and passenger side mirror adjustment and mirror heater
• Actuation of the entrance and interior lamp
• Central locking (ZV)

17 Door Module
• Power windows
High line
• Driver and passenger side mirror adjustment and mirror heater
• Actuation of the entrance and interior lamp
• Comfort locking system (KSA)
• Power window with anti-pinch protection (with KSA only)
Door control panel
The control panels are integrated in the door panel and easily accessible for the driver. The op-
erator request is communicated to the control unit via the door control panel. Functions lo-
cated on the passenger side can be actuated from the driver side.
Door control panel TT_72_29_005784_FA

18 Rain/Light Sensor (RLS), Connective Logics
0 Instructions

Instructions
18.1 Rain/Light Sensor (RLS)
The participant can describe the design of the RLS.

The participant can describe the function of the RLS.
The participant can describe the communication paths of the RLS.
General description of the RLS, design and function of the rain sensor, design and function
of the light sensor
10 min
18.2 Function Pins
The participant can state and understand the connective logics.

AND, OR connectives

18 Rain/Light Sensor (RLS), Connective Logics (Participants)

A combined rain/light sensor (RLS) is installed in the ACTROS3 as special equipment for ex-
panded functions of the windshield wipers and illumination.
This sensor detects:

• Any drops of water on the windshield
• Variations in light conditions on the road surface
The wipers or exterior lights can then be activated, depending upon the operating precondi-
tions.
Design of rain sensor subfunction
The rain sensor operates according to the optoelectronic principle. There are three IR LEDs for
this (infrared light-emitting diodes) as the light source, and three photodiodes to receive the in-
frared light emitted in the electronics of the RLS.
Operation
Picture A:
When the windshield is dry, the light from the LED is reflected as a result of the refraction at
the boundary between the glass and air and conducted to the photodiode via the optical sys-
tem. This takes place with virtually no loss. This makes the intensity of reflected light very high.
The photodiodes measure this high light value.
Picture B:
When the shield is wet, part of the light is scattered outward by the drops of water. This means
that only a part of the emitted light reaches the photodiodes. Thus, the intensity of the light
measured by the photodiodes is lower. The lower the light intensity measured, the "wetter" the
window.

Function of RLS P_82_30_000209_SW
1 RLS (rain/light sensor) 3 Photo diode
2 IR-LED (light emitting diode) 4 Windshield
Design of light sensor subfunction
The light sensor consists of two photodiodes located in the RLS electronics. One of the photo-
diodes (2) is directed forward onto the roadway. It measures the front area light of the vehicle
in a narrow cone. The other photodiode (3) is pointed upwards and measures the absolute
brightness of the ambient light.
If, for example, the photodiodes which are pointing forwards and upwards detect that the light
intensity is reducing, the electronics recognize that the vehicle is driving through a tunnel. If the
light switch is in the "Auto" position the driving lights will be activated.
If both diodes measure a constantly low intensity, then the electronics system recognizes
"darkness" or "dusk". If the light switch is in the "Auto" position, the driving lights will be acti-
vated. If there is low intensity measured on the upper diode and only slightly higher intensity
measured on the photo diode directed towards the front, the electronics recognize passing un-
der a bridge and the driving lights remain switched off.

TT_54_00_005774_FA
1 Windshield 3 Photo diode pointing upward
2 Photo diode pointing to roadway
Note
The sensor is not able to detect fog or snow and therefore the driver will continue to have
to activate the lights himself/herself.
RLS communication in Actros

The communication between the RLS and the base module takes place via LIN bus.
Establishing communication at the LIN bus
When the ignition is switched on, the rain/light sensor is supplied with 12V voltage by the base
module. The LIN master in the BM opens communication on the LIN bus. The information re-
quired for LIN bus functions is requested from the LIN slaves. Requests for information on the
CAN bus are answered by the LIN slave in the BM. The other LIN slave modules are also in-
formed about information relevant for their functions. If all internal and external preconditions
are met for a wiper or light function, the RLS gives the base module a positive answer to the re-
spective function requests.
Precondition for LIN bus communication
The base module opens communication on the LIN bus only if e.g. the RLS in the base module
is parameterized as "present".
Function requirements for automatic wiper function
External (CAN bus) Internal (RLS)
Status of terminal 15 Measurements of the IR receiver diodes in the
RLS
Wiper lever position


Vehicle speed
Outside air temperature
Sensitivity level
Thus, e.g. at a temperature of < 4 °C with terminal 15 switched on and a standing vehicle, the
automatic wiper function will not be performed.
Function requirements for automatic light function
Status of terminal 15 Measurements of photo diode
Light switch position
Engine running
Operation of the RLS

Pitman arm
The pitman arm is connected to the master module. Switch signals of the pitman arm are read
in by the master module, monitored, and transmitted via CAN to the base module.
Functions:
• Left/right turn signal
• Low beams/high beams
• Headlight flasher
• 3-stage wiper: Intermittent wipe (rain sensor function), window wipe/wash, touch wiping
• Horn
Exterior lamp switch
The position of the rotary light switch is read in by the master module via microswitches and
thus the respective switch position is recognized. The switch is monitored and interpreted by
the modular switch panel and the switch position is transmitted to the base module.
Functions:
• Automatic (light sensor function)
• Standing lights
• Low beams
• Front fog lamps
• Rear fog lamp
Repair information
The rain/light sensor must always be replaced after it has been removed as the bonding
surface is destroyed when the sensor is detached. (Refer also to WIS document AR82.00-
W-1000A)

18.2 Function Pins
18.2 Function Pins

Free parameterizable functions may be used to realize customer-specific functions. These are
based on two different logics: the AND combination and the OR combination.
AND combination
With an AND combination, all the input conditions must first be met simultaneously to activate
the output function.
Logic AND TT_54_00_006661_SH
& AND I2 Input condition 2
e1 Input condition 1 A1 Output function
OR combination
With an OR combination, the output function will be activated if just one of the input conditions
is fulfilled.
Logic OR TT_54_00_006663_SH
>=1 OR I2 Input condition 2
e1 Input condition 1 A1 Output function
Function Pins in the Base Module

The diagram shows the function equation for the function pins 15, 18, and 21 at plug X12 of
the base module. The possible combinations of a function pin are illustrated using the diagram.

18.2 Function Pins
Equation for function pins 15, 18, and 21 TT_54_00_005758_SW
Note
• The outputs of the function pins may be loaded with max. 0.5 A.
• Connected inductances (solenoid valves, relays, etc.) must be equipped with an over-
load diode.
• The parameters of the function pins can be parameterized using DAS. The parameteri-
zation can be conducted under the menu item "Parameters for body manufacturers".
• Before parameterizing the function pins, it must be checked whether the particular
output at the base module is used for other purposes.
• Examples for the correct use of potential and function pins are described in the WIS
document SI 54.21-W-0013A.
• The factory preprogramming can be changed using DAS.
Preprogramming of function pins

The function pins are factory-programmed as follows:
Function pin 1: X12 21/15
E1: Retrofitted switch 1 operated
E2: High beam operated
Logical connective type: AND

E2: Standing lamp operated
Logical connective type: AND

E2: NOT ASSIGNED
Logical connective type: OR

18.2 Function Pins

E1: Not assigned
E2: Not assigned
E3: NOT ASSIGNED
E4: NOT ASSIGNED
Threshold value and hysteresis

What is a threshold value?
A threshold value describes the minimum value for a signal.

What is hysteresis?
The hysteresis describes the maximum amount by which the threshold value may be undershot
with the equation still regarded as being met.
An example of this:
A customer operates a large power take-off and would like to actuate an additional electric fan
at the cooler. To this end, he makes the request that the fan should be switched on at 90 °C
and above and remain switched on until the coolant has cooled down to below 80 °C. The
threshold value is consequently 90 °C and the hysteresis 10 °C.
TT_54_00_005759_SW
Function pin 17
Function pin 17 at plug X12 in the GM is implemented by means of an expanded function equa-
tion. Up to 4 CAN events or switch signals from the modular switch panel can be linked. This 4th
function pin is available as of base module version "Release 2". On vehicles with 2 NR operating
units, this function pin is used as part of the control.

18.2 Function Pins
Equation for function pin 17 TT_54_00_006665_SW

19 Battery Disconnect Switch
0 Instructions

Instructions
Total time ...........................................................................................................................20 min
19.1 Battery Disconnect Switch in GGVS vehicles (hazardous goods vehicles)
The participant can explain the notion of GGVS (Regulations for the Transportation of Haz-
ardous Goods).
Hazardous Goods Transport Regulations
2 min.
19.2 Battery Disconnect Switch in ATEGO2/AXOR2
The participant can state the special technical features and their functions in the
Atego2/Axor2 with GGVS equipment.
Battery disconnect switch design and functioning
10 min
19.3 GGVS Functions in the Actros
The participant can state the special technical features and their functions in the Ac-
tros2/3 with GGVS equipment.
Battery disconnect switch design and functioning
8 min.

19.1 Battery Disconnect Switch in GGVS vehicles (hazardous goods vehicles)
19 Battery Disconnect Switch (Participants)

19.1 Battery Disconnect Switch in GGVS vehicles (hazardous goods vehi-
cles)
GGVS means:
They contain guidelines on the domestic and international transportation of hazardous goods
on roads. Hazardous goods are substances or objects which because of their properties are
able during transportation to endanger public safety, the life and health of people and animals
or the environment. Vehicles that fall within the scope of the Hazardous Goods Road Transport
Regulations (GGVS) have several special technical features. These are connected to the con-
struction regulations of the Hazardous Goods Road Transport Regulations.
The special technical features in the ATEGO2, AXOR2 and ACTROS concern the following areas
in the on-board electrical system:
• Lines
• Battery disconnect switch
• Drive switch
• Permanent current circuits
19.2 Battery Disconnect Switch in the ATEGO2 / AXOR2

A battery disconnect switch is part of a GGVS-compliant on-board electrical system, as it is
used to separate the vehicle batteries from the on-board electrical system in emergency situa-
tions. It must be operable via 2 EMERGENCY OFF switches on the vehicle.
The separation of the batteries from the on-board electrical system in the ATEGO2/AXOR2
takes place using an electrically operated battery cutoff relay (K2) in the battery box. The bat-
tery cutoff relay is actuated by the GGVS control unit (A5). Activation of an EMERGENCY OFF
switch or turning the ignition key to the rest position causes the GGVS control unit to switch off
the battery cutoff relay.
The interruption of the on-board electrical system is differentiated into two operating situations:
• EMERGENCY OFF:Activating an EMERGENCY OFF switch causes the control unit to recog-
nize an emergency situation, so the actuation of the battery cutoff relay is immediately in-
terrupted and the on-board electrical system has no voltage. Electrical supply to the con-
sumers is then no longer possible with the exception of the tachograph. The engine is
turned off as well.
• Turning the ignition key in the rest position:This is not a GGVS hazardous situation. The on-
board electrical system does not need to be separated from the battery immediately. To
prevent the battery disconnect switch from separating the consumers from the on-board
electrical system immediately, the GGVS control unit is informed via diodes of so-called hold
conditions. The battery cutoff relay is energized until the holding conditions are no longer
active. Approx.10 s after the last hold condition has disappeared, the on-board electrical
system is separated from the batteries. Hold conditions include: standing lights, hazard
warning flasher switch, stationary heater run-on, INS in run-on state, ZV/KSA ….

Conditions Battery is disconnected from the on-board

electrical system ...
The ignition is switched off ... approx 10 s after "Ignition OFF“
An emergency off switch is actuated ... immediately
The ignition is switched off but a hold condition is ... approx. 10 s after the hold condition is no
still active longer active.

Battery disconnect switch components
N_54_25_002639_FA
TT_54_25_006666_FA
2 Frame switch S109

Dash support switch
1
S5
N_54_31_002020_FA
A1/1 Fuses/diodes
A2/2 Fuses/diodes
A31/3 Tml. 15 relay
N_54_15_002139_SH
1 Battery disconnect switch

Distribution box for ground connec-
2
tions
3 Locking clip
4 Fuse box, positive
5 GGVS control unit

Functions ATEGO2 / AXOR2

actuation The separate GGVS control unit in the battery box actuates the battery discon-
nect switch as soon as tml. 15 is switched on, supplying the on-board electri-
cal system with voltage. If an EMERGENCY OFF switch is operated, the circuit
breaker is de-energized.
Relay Monostable relay
Disconnects the battery from the on-board electrical system automatically
after a certain amount of time. The working contacts of the relay remain closed
only through permanent actuation.
Holding function The disconnection of the battery disconnect switch is prevented, if necessary,
by actuating the control unit via diodes.
Terminal 15 The control electronics receive the information that tml. 15 should be activated
via the drive switch and actuate the relay. The vehicle is thus supplied with
voltage.
Engine stop func- The voltage supply to the FR and the MR is made available via a relay when
tions tml. 15R is activated. The relay is switched by the GGVS control unit.
Diagnosis No diagnosis


A GGVS compliant Actros acts like an Actros without GGVS equipment in normal operation. The
radio remote control and the convenience locking system have the same functionality. The ta-
chograph is supplied with voltage by the battery disconnect switch K2 (BTS) via a fuse. The on-
board electrical system is not separated from the battery until at least one of the two EMER-
GENCY OFF switches is operated. If a GGVS situation occurs, the control unit informs the base
module (BM) by means of a PWM signal, whereupon tml. 15 is switched off for all consumers
and therefore the engine, too. The information "EMERGENCY OFF actuated“ is transmitted via a
separate line between the BTS and the base module.
PWM signal to the base module
EMERGENCY OFF not operated 40 ms to 40 ms = 50%
EMERGENCY OFF operated 20 ms to 60 ms = 25%
The battery disconnect switch (K2) is connected to the base module via the frame CAN and can
thus be diagnosed.
Battery disconnect switch with integral rear end W_54_10_001038_SW
K2 Battery disconnect switch
Functions Actros
actuation If neither of the switches is operated, the battery disconnect switch is
switched on by the electronics integrated in the switch. If an EMERGENCY OFF
switch is operated, the circuit breaker is de-energized.
Relay Bi-stable relay
The relay remains in a stable condition by two permanent magnets. It receives
a pulse and then remains in this position until another pulse is applied.
Holding function No longer necessary, since the battery disconnect switch actuates the relay
only after an EMERGENCY OFF has been operated.
Terminal 15 Tml.15 is necessary as a wake-up signal for the electronics.

Functions Actros
Engine stop func- The battery disconnect switch sends the information "EMERGENCY OFF" to the
tions base module via a PWM signal if an emergency off switch has been activated.
The GM switches off tml. 15 for the drive/engine control control units.
Diagnosis The BTS is connected to the base module via the frame CAN.
• Monitoring of the EMERGENCY OFF switches
• Monitoring of the battery disconnect switch state
• Display of the events in the Instrument

20 Antennas
0 Instructions
20 Antennas
Instructions
Overall duration...................................................................................................................5 min.
20.1 Antennas
The participant can name the installed antennas.

Overview of antennas
5 min.

20 Antennas
20.1 Antennas
20 Antennas (Participants)
20.1 Antennas
Many different types of antennas are installed in the Atego2, Axor2 and Actros3 model series.
Actros roof antennas TT_82_62_005710_FA
In everyday workshop situations, they are mostly differentiated according to their use:
FleetBoard® and Toll Collect antennas
These antennas are designed as multifunction antennas for receiving GSM and GPS signals, as
well as sending GSM signals.
GSM or multifunction antennas
The GSM antenna is designed as a multifunction antenna, either in combination with the radio
antenna or in combination with the GPS antenna. Technically the GSM antenna is a tri-band an-
tenna for GSM 900, GSM 1800 and UMTS.
Toll Collect antenna
They have the same technical function as the above mentioned antennas, but they are differen-
tiated by the replacement parts and warranty divisions, even if the designs are identical. The
separate designation serves to distinguish the Toll Collect antenna, as it is the official property
of the Toll Collect Consortium. This must be taken into account in complaint and warranty
cases. Toll Collect also has official property rights for the wiring harness and other compo-
nents.
Radio antenna
The radio antenna is available in 2 versions. As strictly a radio antenna for analog radio (FM to
AM) or as a multifunction antenna in combination with GSM. The radio antenna is designed ei-
ther as a window antenna, a rod antenna or a multifunction antenna in combination with a GSM
antenna. Radio antennas are not yet designed to receive DAB (Digital Audio Broadcast). If a
DAB radio is to be used, the corresponding antenna must be retrofitted.
CB radio antenna
The CB radio antenna comes in 2 variants, which are mechanically distinguishable only at the
antenna base. This antenna is designed as a rod antenna for sending and receiving CB radio
20 Antennas
20.1 Antennas
signals. They can be adjusted in order to set the standing wave ratio using the standing wave
measuring unit.
Retrofitting
When retrofitting antennas, observe that the permissible vehicle height (4 m) is not exceeded.
(Danger of damage due to high voltage during rail transportation). For this reason, different
base variants are available as accessories for radio antennas.
Installation locations of the antennas

The number and form of the possible antennas differ according to equipment, model series and
roof form (high or low roof).
Actros3 normal roof
Full equipment TT_82_62_005711_FA
1 Radio/mobile phone antenna 4 Navigation antenna
2 FleetBoard® antenna 5 CB radio antenna
3 Toll Collect antenna
Actros3 with high roof

20 Antennas
20.1 Antennas
1 Radio/mobile phone antenna 4 Navigation antenna
Vehicles with low roof
1 Radio antenna 4 Navigation and telephone antenna

21 Practical Work 8
0 Instructions
21 Practical Work 8
Instructions
21.1 Wiring Diagram Exercise for GGVS Axor2
Group work in 3 groups:
Group 1 on wiring diagram exercise for GGVS Axor2, theory
Group 2 on troubleshooting in Axor2
Group 3 on parameter setting at function pin 17 in Actros3
Training room/ 45 min
Workshop
21.2 Troubleshooting at the Axor2
Workshop
21.3 Parameter Setting at Function Pin 17
Workshop

Training room/ 20 min.

Workshop

21 Practical Work 8

Exercise 53 Fill in the missing information on the components for the GGVS function using the circuit dia-
gram for help.
TT_54_00_006714_SH
Component Information
K5/A37
Terminal 15 FR/MR
Arrow at relay K2
On-board electrical system power supply
K2
BTS disconnect switch
S1
Drive switch 15R
S109
Frame EMERGENCY OFF
S5
Cockpit EMERGENCY OFF
V1
Standing lights
V2
Hazard warning flasher
V3
Auxiliary heater
V4
CL/CLS
V5
Instrument

21 Practical Work 8
Exercise 54 Which statements about the V1-V5 diodes are correct? Mark the correct answers with a cross.
With ignition off the K2 relay remains actuated as long as there is hold voltage
at the A5 control unit. X
Applying voltage to the diode output energizes the K2 relay.
The K2 relay remains energized and supplies the hazard warning system with
voltage as long as the hazard warning system and EMERGENCY OFF switch
are activated.
With an activated EMERGENCY OFF switch information from the diodes is no
longer considered and the power supply to the on-board electrical system is X
immediately interrupted.
Diode V3 makes it possible for the auxiliary heater to run-on after terminal 15
has been switched off. X
Exercise 55 What tasks does relay K5/A37 perform in the GGVS function?
Terminal 15 to FR/MR is interrupted when the EMERGENCY OFF switch is

actuated.
Explanation: When the engine is running the alternator continues supply-
ing voltage to the on-board electrical system, so that no discontinuity to
the on-board electrical system could occur.
Exercise 56 What are the differences in terminal 15 circuits for FR/MR in vehicles…
a) ... not subject to GGVS
Drive switch – base module X9 (tml.15) – FR/MR
b) ... subject to GGVS
Drive switch – GGVS CU A5 – K5/A37 – FR/MR

21 Practical Work 8

Exercise 57 Enter the task assigned by the trainer.
Important: Make separate notes on each logical and practical step.
Level Question Answer
Level 1 What background information do you
have on this complaint?
Level 2 Which systems/subsystems could be
associated with the complaint?
Level 3 What tests shall I perform and how?
Level 4 What could have (actually) caused the
defect?
Level 5 How do I carry out the repair and how
do I check if the fault is consequently
eliminated?
Exercise 58 Enter the task assigned by the trainer.

Important: Make separate notes on each logical and practical step.
Level Question Answer
Level 1 What background information do you
have on this complaint?
Level 2 Which systems/subsystems could be
associated with the complaint?
Level 3 What tests shall I perform and how?
Level 4 What could have (actually) caused the
defect?
Level 5 How do I carry out the repair and how
do I check if the fault is consequently
eliminated?

21 Practical Work 8

Exercise 59 A customer would like to actuate a consumer with the following preconditions:
The output of the function pin should be actuated if:

• The reverse gear and the hazard warning system are activated simultaneously, or:
• The retrofitted switch 2 is actuated and 3rd gear is engaged.
• A gear lower than 2nd gear is engaged afterwards, the condition should be considered not
fulfilled.
• The output should be switched off after a delay of 1.5 seconds.
Discuss the parameters needed for the function in the group.
Enter the parameters in the picture.
Then transmit the parameters into the necessary parameter list in the base module.
Aids: DAS/workshop literature.
Exercise 60 Use the "power take-off solenoid valve" model
Connect the model to the vehicle and check the function.
Name the required test steps/test prerequisites.
The threshold values and hysteresis are not correct for constant-mesh
transmissions.

21 Practical Work 8
Exercise 61
TT_54_00_006665_SW


22 Retrofitting Electrical Consumers
0 Instructions

Instructions
Total time ..........................................................................................................................70 min.
22.1 Notes on Product Liability
The participant can state liability criteria and risks of accidents as a result of retrofitting.
Product liability
22.2 Rules of Conduct for Retrofit Work on Electrical Consumers
The participant can state the basic rules of conduct for protecting
consumers, cable routing, wired connections, power supply
and indicator lamps when retrofitting the vehicle.
Rules of conduct
22.3 Cable Passages
The participant can describe the necessary and different possibilities

for sealing cable passages.
Notes on the correct cable passages
22.4 Retrofitting Control Units
The participant can state and justify the necessary operations for retrofitting a
control unit.
Procedure in retrofitting CU
22.6 Adapter Cable and Y-cable
The participant knows the schematic design of a Y-cable.

Manufacture Y-cable

0 Instructions
22.7 Retrofitting Switches
The participant knows the schematic circuitry of load switches.

The participant knows the method of operation of the background illumination.
The participant knows the method of operation of the indicator lamps.
Design and retrofitting of switches
Summary of 3rd Day

10 min

22 Retrofitting Electrical Consumers (Participants)

With regard to product liability, attention is drawn to the following points:
Every manufacturer is liable for the product it manufactured in the event that this does not ex-
hibit the operational safety required.
As a manufacturer, Daimler AG is only liable for Mercedes-Benz vehicles within the scope of its
own design and production services. Daimler AG shall therefore not accept any liability for
damages resulting from retrofitted subproducts produced by other manufacturers.
The vehicle body manufacturer/modifier is therefore solely and independently responsible, for
example, for:
• Operational and road safety of the body
• Operational and road safety of parts and modifications
• Testing and maintaining the operational and driving safety of the overall vehicle after the
body/equipment is mounted (the equipment must not have a negative effect on driving,
braking and steering characteristics)
• Effects of parts or modifications on the chassis
• Consequential damage resulting from the mounting, attachment, installation or modifica-
tion.
• Consequential damage resulting from retrofitting electrical and electronic systems
• Maintaining the functional reliability and the unobstructed movement of all movable parts of
the chassis after the body/equipment has been mounted (e.g. axles, springs, propeller
shafts, steering, gearshift linkage, etc.), even in the case of diagonal torsion with respect to
the bodies.

Principle
• Switch off all consumers and disconnect negative terminal from the batteries.
• Do not reconnect batteries until all disconnected lines have been reconnected.
• Do not disconnect or connect connector to the control units with the ignition on.
Protecting consumers
• Installations on the electrical system must be carried out with short-circuit protection.
• Retrofitted consumers must be protected by additional, adequately rated fuses.
• Further consumers must not be connected to assigned fuses.
Cable routing
• Do not secure cables to air lines or battery cables.
• Lines must be protected from the effects of heat using corresponding insulation.
• Lay cable so that no chafe marks arise; if necessary, use cable ducts or guide tubes
• Adequately protect cable passages to the interior compartment from the ingress of mois-
ture.
• Ensure size of cable cross section suffices for consumers.
• Do not use vehicle frame as ground line.
Cable connection
• Only use tested and approved plugs at the ends of lines.
• Do not damage cable seal at plugs in the exterior area.
• Only use approved crimping tools.
• No twin wire connectors at plugs and couplings.
Voltage Supply
• Powerful electrical consumers > 10 A must not be powered or connected via the base mod-
ule.
• Connect feed line for powerful electrical consumers to the power distributor via additional
adapter boxes.
• The current studs at the base module must not be used for tapping the current.
• Do not connect additional lines to existing lines (e.g. using insulation displacement connec-
tors).
• It is not permissible to pick up signals at the control units.
12-volt consumers
• For 12-volt devices the current may only be tapped by means of a voltage converter.
• It is not permissible to tap the current at just one battery.

Installation parts in tractor and trailer vehicles

• Use equivalent parts from the available SA code where possible.
• When retrofitting additional inductances (e.g. solenoid valve), the induced voltage must be
deleted by an overload diode when switching off.
• Only solenoid valves and relays with integrated overload diodes may be used.
Indicator lamps
• Additional indicator lamps can be fitted in the instrument panel.
• When the lamps are connected to the intended pin of the Instrument, dimmed display is
possible.
Dimensions
• Do not perform any measurements at the contact point of connectors using unsuitable
means (probes, wire ends, etc.).
• Use appropriate test cables.
Notes on cable repair in WIS WIS no.
Repair of cable sets AR54.18-W-0105A
Crimping electrical contact crimps AR54.18-W-0010B
Notes on working with crimps AH00.19-n-1000-09fs
Check crimp connections AR54.18-w-0110-01A
Repair of cable sets AH54.18-N-0001-01A
Extending cable sets AH54.18-N-0001-01B
Information
Tampering with electronic components and their software can cause malfunctions in the
electronics and considerably endanger the operational safety of the vehicle. Due to the
networking of the electronic components, this could even affect systems that were not
modified.
Current information on body/equipment mounting directives can be found in the Internet:

• MBVD operations in sales portal: http://intra.dcvdnet.de/mb/lkw/index.jsp on
tab: New vehicles/abh-infoportal
• Other operations: http://abh-infoportal.mercedes-benz.com

22.3 Cable Passages
22.3 Cable Passages

For additional cable passages at the cab chassis connector (cab/frame separation point), it
must be carefully ensured that the passage is sealed. This can be done by means of various ac-
cessory parts, such as reducing pieces, stop plugs or corrugated hoses. If not sealed ade-
quately, moisture may enter the interior compartment along the lines as a result of capillary ef-
fects. Water droplets may form at the end of the line, usually at the connector of the connected
control unit, and these will cause irreparable damage to the control unit. A proper seal looks
like this:
Cable passage TT_54_18_005785_FA
Reducing piece TT_54_18_005787_FA
Note
In line with this principle, this should be provided not just at the cab/frame separation
point, but for all sealed line passages.


For additional functions the retrofitting of a control unit in a vehicle is sometimes unavoidable.
An example of this is the parameterizable special module, abbreviated to PSM.
The following points must be kept in mind with the ACTROS:

• Creation of the electrical connections for power supply and CAN bus as per the circuit dia-
gram.
• Parameterization of the control unit list in the base module plus subsequent updating of
CDM in GM.
• In the central data memory: Retrofitting of a control unit plus subsequent updating of CDM.
• Parameterization of the control unit list in INS plus updating of CDM.
• Teach-in of the CAN environment in the drive control control unit (FR) or in the Common
Powertrain Control (CPC) control unit
PSM control unit TT_07_08_005788_FA
The updating of the CDM must be carried out. This will ensure the availability of up-to-date
backup copies in the vehicle for all control units in which a parameter was changed. The mirror
memory in the Instrument is automatically updated when the CDM is updated. The new struc-
ture of the CDM is then also stored as a backup copy.

22.5 Retrofitting Indicator Lamps in the Instrument
22.5 Retrofitting Indicator Lamps in the Instrument
Instrument 2002 / 2008

Up to 8 additional indicator lamps can be retrofitted in the Instrument of the ACTROS. These
indicator lamps must be wired separately. Two variants of the wiring are possible depending
upon the use and the legal requirements for indicator lamps:
1. A dimmed power supply for additional indicator lamps can be tapped at plug X2 18/4 of
the Instrument. The indicator lamp output is connected via an additional control switch to
ground.
2. The indicator lamps are wired independently of the Instrument.
The fitting symbols for indicator lamps are available, which can be affixed to the slide-in card.
Left symbol disk TT_54_30_005789_SW
Right symbol disk TT_54_30_005790_SW
Note
A sheet with the most common symbols can be ordered from the parts department of
Mercedes-Benz using the following part number: A 000 584 44 38


To connect additional consumers (e.g. additional lamp units) to existing wiring, a Y-cable must
be prepared and used on the outside of the vehicle. This is attached to the vehicle's cable set
using a plug, which corresponds to the socket of the original consumer. The signals are picked
up in the line of the Y-cable via J-connectors and made available for end consumers at two
plugs.
When making the Y-cables, the following must be noted:

• The cables in the J-connector must be soldered.
• The J-connector must be bonded watertight using a suitable heat-shrinkable tube.
• The functioning of the single-wire seal at the plugs must be ensured.
Y-cable
Y-cable TT_54_25_006678_FA
TT_54_25_006679_SH
Key to picture:
Top right: Socket identical to the original con-
sumer
Bottom right: Plug identical to the genuine cable
set
Left center: Plug fitting for retrofitted consumer
Important
When retrofitting additional consumers, the maximum power consumption of the control
unit outputs may not be exceeded.


In the ACTROS it is possible to retrofit switches for electrical accessories in the modular switch
panel (MSF). The MSF consists of a control unit, the master, and several switch panels, the
slaves. The switches to be retrofitted can be inserted in any slot of the MSF. There are two dif-
ferent types of switches to choose from: ASIC switches (also called signal switches) and load
switches.
ASIC switches:
• Are connected at the ASIC bus to the master
• Transmit their switch position via the ASIC bus to the master
• Receive the status of the background illumination via the ASIC bus
• Receive the information for the indicator lamp of the switch state via the ASIC bus
• Can be positioned freely within the MSF system
Load switches
• Are connected at the ASIC bus to the master
• Receive the status of the background illumination via the ASIC bus
• Switch electric circuits conventionally as normally closed contacts/normally open contacts.
• Switching current max. 5 A
• Permanent current max. 20 A
• The indicator lamp for the switch state is picked up internally via the load circuit in the
switch
Load switch TT_54_25_005791_SW
Observe the following points when installing the switches:
All switches function correctly immediately after installation. To ensure correct fault monitoring,
switches must be registered in the MSF control unit. Furthermore, a load switch must also be
connected to the electric circuit to be opened/closed.

23 Voltage Sources
0 Instructions
23 Voltage Sources
Instructions
Overall duration:................................................................................................................50 min.
Review of 3rd day

Clarify unanswered questions from the 3rd day, call-out questions
Presentation, interactive lecture 10 min
23.1 Voltage Sources on the ATEGO2/AXOR2
The participant can name the different voltage sources of consumers.

The participant can state the load limits of the voltage sources.
The participant can state options and preconditions for connecting large consumers.
Plug X7.1, battery terminal
5 min.
23.2 Voltage Sources on the ACTROS2/3

Plug X7, power distributor, battery terminal
5 min.
23.3 Power Supply in Trailer/Semitrailer Greater than 10 A
Trailer/ semitrailer above 10A
10 min
23.4 Voltage Converter 12 V

Atego2/ Axor2 and Actros2/3
5 min.

23 Voltage Sources
0 Instructions
23.5 Practical Work on Voltage Converters
The participants can apply the acquired theoretical content in

practice.
Fuse protection and wiring
15 min.

23 Voltage Sources
23.1 Voltage Sources at the ATEGO2/ AXOR2
23 Voltage Sources (Participants)

When retrofitting additional consumers on the ATEGO2/ AXOR2 the consumers must first be
considered more carefully.
12V consumers must be connected via an installed voltage converter. If the consumer is con-
nected to one of the two vehicle batteries, these will no longer be charged correctly by the al-
ternator.
24V consumers consuming less than 10 A of power may be tapped at plug X7.1 at the
cab/chassis interface in the electrical compartment.
W_54_00_001007_SH
Pin assignment of plug X7.1/18

Pin 1 Terminal 30 Max 10A
Pin 2 Tml. 31 Max 10A
Pin 3 Terminal 15 (F39, 10A) Max 2A
Pin 4 Terminal 58 (F2, 10A) Max 2A
Pin 5 Terminal D+ (F7, 15 A) Max 2A
Pin 6 Backup lamp (F34, 10 A) Max 2A
Pin 7 Tml. W Max 10 mA
Pin 8 v signal Max 10 mA
Pin 9 TCO additional recorder
Pin 10 TCO additional recorder
Pin 11 Not assigned
Pin 12 Not assigned
Pin 13 Load compartment lamp negative (SA)
Pin 14 Load compartment lamp positive (SA)
Pin 15 PSM remote clutch control (SA)
Pin 16 PSM remote clutch control (SA)
Pin 17 Not assigned
Pin 18 Not assigned
Note
The total amount of power tapped at plug X7.1 is limited to 10 A.

23 Voltage Sources
Retrofitting accessories with consumption > 10 A

For supplying power to electrical consumers greater than 10 A, these are connected via addi-
tional fuse boxes in the battery box. The cross section of the supply line must be designed for
the amperage of the accessories.
The following basic rules are used for this:
The maximum current density of a line depends on its cross section. From 1 - 10 mm² it is 8
A/mm². From 10 - 35 mm2 it is 6 A/mm2. The voltage loss here from the battery to the con-
sumer must not exceed 0.5 V! If, because of the line length, it exceeds 0.5 V, then the next lar-
ger must be selected.
N_54_15_002139_SH
1 Battery disconnect switch 4 Fuse box, positive
2 Distribution box for ground connections 5 GGVS control unit
3 Locking clip
Example
A consumer with a consumption of 40 A is to be connected. With a maximum current density of

6 A/mm² there is a line cross-section of 6.6 mm². Since this line cross section is not available,
the next highest line cross section of 10 mm² must be used.
Current tap of >10A at battery terminal

As an option to the current tap at the retrofitted power distributor, the current taps can also be
made at the battery terminals if necessary.
Prerequisite:
There is a terminal clamp with a conical threaded connection and contour at the ends of the
battery lines. In vehicles manufactured as of February 2008, battery clamps with a conical
threaded connection are installed. There is a stud on the battery terminals of the standard in-
stalled battery lines. Retrofitted lines can be screwed directly onto the studs.

23 Voltage Sources
Note
The conical threaded connection on the battery terminal may not be used for current taps!
Maximum tap is 160 A. For older vehicles retrofit battery terminals can be installed on the
battery lines.

23 Voltage Sources
23.2 Voltage Sources at the ACTROS2/3

When retrofitting electrical accessories on the ACTROS2/3 the consumers must first be exam-
ined more closely.
12V consumers must be connected via an installed voltage converter. If the consumer is con-
nected to one of the two vehicle batteries, these will no longer be charged correctly by the al-
ternator.
24V consumers consuming less than 10 A of power may be tapped at plug X7 of the base
module.
W_54_21_001269_SW
Pin assignment for plug X7/9 at the base module:

Pin 4 Backup lamp Max 2A
Pin 5 Tml. W Max. 50 mA
Pin 6 Tml. D+ Max 2A
Pin 8 v signal Max. 50 mA, 8 pulses/m
Note
The total amount of power tapped at plug X7 of the base module is limited to 10 A.
Individual outputs of plug X7 at the base module are routed via a fuse together with other
consumers. Details on this can be found in the circuit diagram PE54.21-W-2400K.
Retrofitting accessories with consumption > 10 A

Power must be supplied to retrofitted electrical consumers greater than 10 A via additional cur-
rent taps at the power distributor. There the positive and negative potential are tapped. The
positive line can be protected from short-circuit in the tap by means of a fuse with a value of
100 A, 150 A or 200 A. To assure a reliable single-wire seal these taps are available in 2 cable
cross-section versions (16 mm² or 50 mm²).

23 Voltage Sources
TT_54_10_006581_FA
The cross section of the supply line must be designed for the amperage of the accessories.
The following basic rules are used for this.
The maximum current density of a line depends on its cross section. From 1 - 10 mm² it is 8
A/mm². From 10 - 35 mm2 it is 6 A/mm2. The voltage loss here from the battery to the con-
sumer must not exceed 0.5 V! If voltage loss exceeds 0.5 V because of the line length, then the
next larger line cross-section must be selected.
A total of up to 3 such current taps are possible on the power distributor. However, the tap
must not exceed 200 A in total. If current taps are required for additional consumers, the power
consumption of which is more than 10 A either individually or in total, retrofitting of SA code
KEVR is recommended. In this case, a screw bolt in the cab/chassis interface is connected to
the positive potential with the aid of the taps at the power distributor and a 16 mm² line. The
ground connection is provided via an additional 16 mm² line that is fitted onto the screw bolt at
the base module. Current taps up to 100 A can then be implemented using the 16 mm² line and
by selecting the appropriate fuse.
Note
Further information is available in WIS: AN54.18-W-2000MP
Current tap of >10A at battery terminal

As an option to the current tap at the retrofitted power distributor, the current taps can also be
made at the battery terminals if necessary.
Prerequisite:
There is a terminal clamp with a conical threaded connection and contour at the ends of the
battery lines. In vehicles manufactured as of February 2008, battery clamps with a conical
threaded connection are installed. There is a contour on the battery terminals of the standard
installed battery lines (without integral rear end). An M6 thread can subsequently be drilled and
cut in this contour.
Note
The conical threaded connection on the battery terminal may not be used for current taps!

23 Voltage Sources
Maximum tap is 160 A. For older vehicles, proper retrofitting of battery terminals at the
battery lines is possible. In the ACTROS with integral rear end, no modified battery clamp
can be used because of the increased cable cross section (95 mm2). This rules out the
option of tapping at the battery terminals.

23 Voltage Sources

In the commercial vehicle sector, a power supply in the trailer/semitrailer with a power con-
sumption greater than 10 A may be required, depending on the vehicle's application. This may
be necessary, for example, for a second battery pack, a fork-lift truck or the like. When retrofit-
ting such a power supply, the use of a "power plug socket" is proposed because maximum
power consumption will be very high. The wiring is illustrated schematically below:
Power plug socket TT_54_10_006688_SH
Terminal 30 power supply in line with

1 3 Power plug socket
vehicle circumstances
Ground connection in line with vehicle
2
circumstances
The battery disconnect switch relay for Atego2/Axor2 GGVS vehicles is proposed as the relay,
as this is designed for high switching and permanent currents. The relay must be actuated via
terminal D+ to ensure that there is a power supply only when the alternator is operating cor-
rectly.
Note
To prevent damage due to voltage fluctuations, the power plug socket must not be con-
nected or disconnected when the engine is running.

23 Voltage Sources
23.4 12 V Voltage Converter
23.4 12 V Voltage Converter
23.4.1 12 V Voltage Converter

Two different voltage converters are installed ex works, depending on the special equipment
and cab variant ordered.
Atego2/Axor2
8 A voltage converter 15 A voltage converter
• Navigation unit APS 30 • Preinstallation for two-way radio + telephone
• Two-way radio preinstallation + APS 30
• Telephone preinstallation • Preinstallation for two-way radio + telephone
+ 12 V radio
• Hands-free system
• FLEETBOARD preinstallation
• 12V radio preinstallation
• Additional 12 V socket in dash support
ACTROS2/3
8 A voltage converter 15 A voltage converter
• Two-way radio preinstallation • Preinstallation for two-way radio + telephone
• Telephone preinstallation + APS 30
(both standard in Germany) • Preinstallation for two-way radio + telephone
+ 12 V radio
• Additional 12 V socket in dash support
The installation location of the voltage converters is the dash support, near the heater housing,
in these vehicle model series.

23 Voltage Sources

Exercise 62 Which fuse is used to protect the voltage converter T2 on the Actros3?
F13 – A1
Exercise 63 How is the terminal 15 power supply (12 V) implemented at connector X63?
Relay K4 – A31 is actuated with 24 V and switches 12 V voltage to

X63/contact cavity 8
Exercise 64 Which control units can be connected to pin 1 in plug X63?
Radio
SPA (Lane Assistant)

24 Power Take-off via Base Module
0 Instructions

Instructions
24.1 Power Take-off via Base Module
The participant can recognize that the GM is sufficient for the use of simple power take-off
equations.
The participant can name the potential danger when parameterizing power take-off equa-
tions.
Actros3
45 min

24 Power Take-off via Base Module (Participants)

Daytime running lights shutoff with engaged power take-off (code L04)
As of GM version Release 3 it is possible to deactivate the daytime running lights with a stand-
ing vehicle and engaged power take-off. The shutoff is triggered via the power take-off feed-
back from NA1 – NA3 (parameterizable via DAS). Shutting off the daytime running lights is one
way to save on fuel and light sources.
Safety information
This chapter is not sufficient to learn the complex topic of "Parameterizing power take-off
equations“. It is meant only to provide a glimpse of the possibilities and limitations when
dealing with power take-offs. The regulations of the respective country must be observed
when parameterizing power take-offs! The technician carries the responsibility for faults in
power take-off parameterization.
Power take-off in the base module

The power take-off equations shown on the following pages are integrated into the base mod-
ule. This enables you to parameterize simple power take-offs, without installing a PSM (parame-
terizable special module). The power take-off function in the base module is only active when
no PSM is fitted in the vehicle.

TT_54_00_006689_SH
Supplements to the equation

Power take-off request Possible only with signal switch in the MSF
CAN events 1 and 2 2 CAN events can additionally be applied
Feedback in the case of PTO 1 If "feedback" is set to "YES," the "Min rpm" pa-
rameter must be set to "no"!

TT_54_00_006690_SH
Supplements to the equation

Rpm limitation with power take-off Notice: In parameterizing the engine speeds, you
must note the transmission / PTO gear ratios
ADR request and enable ADR request and ADR enable are combined.
Enable takes place only with parking brake and
neutral position.

Functional equation for PTO via base module TT_54_00_006694_SH

25 Practical Work 9
0 Instructions
25 Practical Work 9
Instructions
25.1 Retrofitting on Actros3/Axor2
1 group on the pinboard
1 group at the Actros3
1 group at the Actros3 model board
Training room pinboard 45 min
25.2 Retrofitting the Modular Switch Panel
Training room model board 45 min
25.3 Power Take-off via Base Module at the ACTROS3
on Actros3 45 min


25 Practical Work 9
25.1 Retrofitting on the ACTROS3/AXOR2

Exercise 65 A customer request requires a retrofit on the vehicle. The circuit required on the vehicle is to
be represented on the simulation model with the aid of load switches.
Customer request:
Consumer 1 (red consumer, 300 W) should be activated when the switch on the ATEGO3 is set
to position 1.
Consumer 2 (green consumer, 50 W) should be activated when the switch on the Atego2 is set
to position 2.
In addition, the corresponding indicator lamp in the switch should signal to the driver that the
consumer is switched on.
TT_82_20_006696_SH
Exercise 66 Calculate the power consumption of the consumers and state the required line cross section
for the respective consumer.
Power consumption: Conductor cross section
Consumer 1 in ACTROS3
12.5 A 2.5 mm2
Consumer 2 in ATEGO2
2.1 A 1 mm2

25 Practical Work 9
Exercise 67 Which fuse should be selected?

Consumers Fuse
Consumer 1 in ACTROS3
15A
Consumer 2 in ATEGO2
5A
Exercise 68 Using the example of the Actros3, describe the required signal path for the consumer if the
power consumption is 300 watts?
a) Operating current relay:
• Lead fused terminal 30 from the adapter at the power distributor to the
cab connector
• via a fuse to relay, terminal 30
• from relay, terminal 87, to the consumer
• Lead consumer ground back to the power distributor
b) Control current relay:
• Voltage from X7 to switch

• from the switch to relay, terminal 86
• Tap ground at dash support or lead back to X7 GM
Exercise 69 Where can the signal for the switch illumination be tapped on the ATEGO2?
Body manufacturer interface plug X7.1 contact cavity 4

25 Practical Work 9

Exercise 70 A work lamp is to be retrofitted (with original switch) on a customer vehicle. The procedure is
easy with the comprehensive networking in the Actros3. The function of the work lamp is de-
scribed in the WIS document GF82.10-W-3018MP. Complete the block diagram and draw the
connected modules!
TT_54_00_006697_SH
Switch S30 to the MSF - base module - front module - work lamp
The work lamp is automatically switched off at > 30 km/h.
Exercise 71 Retrofit the switch and the work lamp and answer the questions!
a) What operations are necessary to insert the "Work lamp" switch in the MSF?
Insert switch and parameterize (register at MSF)

25 Practical Work 9
b) What operations are necessary to activate the work lamp in the FM?
Parameterize "Work lamps present" in the FM so that the output will be

actuated.
c) Insert another S30 button in an arbitrary slave module. Actuate this button! What reaction or
impedance do you notice?
Work lamp reacts to the actuation of both buttons

No function impedance noticeable
Exercise 72 A work lamp is to be retrofitted in an Axor2.
Requirement:
The work lamp is to be operable only when the ignition is switched on. The voltage is to be
supplied via connector X7.1 of the cab/frame separation point connector. Complete the prin-
ciple wiring diagram.
TT_54_00_006698_SH

25 Practical Work 9

Exercise 73 A power take-off is to be retrofitted on a customer vehicle via the base module. Retrofit the
solenoid valve and the feedback switch for the power take-off on the vehicle.
a) On which plug and pins are the components connected to the base module?
• Solenoid valve X23/12/3

• Feedback switch X23/12/4
• Ground line X7/9/7
• Insert and parameterize power take-off switch
b) What operations are necessary to activate the power take-off?
• Parameterize power take-off equation in base module

• Enable X23/12/3 output
Exercise 74 Consider which parameters must be changed in the function equation of the power take-off in
the base module in order to fulfill the customer request on the vehicle. Use the diagram of the
functional equation on the following page.
a) Mark the parameters.
b) Implement the specified requirements on the vehicle.

25 Practical Work 9
c) Check to see if all conditions have been met.
The customer expects the following requirements to be met for his dumper vehicle with steel
suspension and transmission-driven power take-off:
Conditions: Function:
Power take-off engageable via switch Actuate solenoid valve.
Engagement of PTO only if engine speed is max. Engine speed max. 1000 rpm
650 rpm
Engagement of PTO in combination with parking ADR mode (RQV)
brake and neutral position
Drive with engaged power take-off at up to 6
km/h
Actuate indicator lamps in Instrument/switch
Torque max. 1000 Nm
Rotational speed can be variably regulated via
the accelerator pedal
TT_54_00_006694_SH

25 Practical Work 9
Exercise 75 Write down the required test steps for checking the vehicle safety with the power take-off en-
gaged.
e.g. release parking brake, request PTO via switch – PTO is not engaged.
Engine speed > 650 rpm, request PTO via switch – PTO is not engaged.
Parking brake released, PTO remains engaged. Vehicle can be moved at
max. 6 km/h.
Exercise 76 Check the response of the MR control type when releasing the parking brake.
Control type with engaged parking brake:
ADR control type
Control type with released parking brake:
LL control type
Fixed rpm via cruise control switch:
OK
Exercise 77 Change the parameter for the "feedback" and the "last engagement condition" to "no".
Then check the altered behavior of the PTO equation with the PTO engaged.
a) Release parking brake:
PTO is switched off
b) Re-engage parking brake:
Despite secured vehicle, the PTO is not re-engaged.
c) Findings:
Despite vehicle being secured, PTO is not engaged again until the PTO
request switch is actuated again.

25 Practical Work 9


26 Compulsory Lowering and Residual Air Bellows Pressure regulation
0 Instructions
26 Compulsory Lowering and Residual Air Bellows Pressure

regulation
Instructions
Total time ...........................................................................................................................30 min
26.1 Compulsory Lowering via Base Module
The participant can describe the compulsory lowering function.

Compulsory lowering for power take-off via GM
26.2 Residual Air Bellows Pressure Regulation via Base Module
The participant can describe the residual air bellows pressure regulation function.
Residual air bellows pressure regulation with power take-off via GM
26.3 Compulsory Lowering and Residual Air Bellows Pressure Regulation via PSM
The participant can describe the compulsory lowering function with residual air bellows
pressure regulation via PSM.
Compulsory lowering and residual air bellows pressure regulation for power take-off via
PSM

26 Compulsory Lowering and Residual Air Bellows Pressure

Regulation (Participants)
When operating a power take-off, particular safety regulations must be followed. Thus, for air-
sprung vehicles with a roll-off container, for example, compulsory lowering of the vehicle frame
must ensue when the power take-off is engaged.
Procedure for retrofitting the compulsory lowering for NA function via the base module
(GM A7).
TT_54_00_006700_SH
• Adapt parameters in the NA equation in GM. Select GM system

Control unit adaptation
Parameters for the body manufacturers
Power take-off
Activate parameter 630 (activation of output X12 21/15).
• Retrofit relay circuit on GM for X12 21/15.
• Activate "compulsory lowering" in the HM. Select HM system in DAS. Parameterization
Level control parameter group
Set parameter 121 to active.
Note
For safety reasons, there is no automatic raising of the vehicle when the power take-off is
switched off. The driver must end the compulsory lowering using the "STOP" button. Then
he can move the vehicle to the required level (e.g. driving level) using the operating unit.
Level control only reacts to the "STOP" button on the operating unit during compulsory
lowering.


To protect the air bellows, the compulsory lowering should be activated in combination with re-
sidual air bellows pressure regulation.
Prerequisite:
• Compulsory lowering is activated and installed.
• The vehicle is equipped with pressure sensors.
• The rear module supports the residual air bellows pressure regulation function.
TT_54_00_006703_FA
To ensure that the engine is running during power take-off operation, a parameterization must
also be conducted on the input side of the NA equation:
Set parameter at "CAN event" of the NA equation to the following values:

PTO Equation
10.180 "FCAN event" "YES"
10.190 "Event block E1.1" Engine speed
(205020080034)
10.200 "Threshold value" 0
Set "Residual air bellows pressure regulation" parameter in HM to "YES".
Information
If there are no pressure sensors installed in the vehicle, these have to be retrofitted. In
addition, a pressure sensor calibration will need to be carried out.

26.3 Compulsory Lowering and Residual Air Bellows Pressure Regulation via PSM
26.3 Compulsory Lowering and Residual Air Bellows Pressure Regulation

via PSM
When operating a power take-off, particular safety regulations must be followed. Thus, for air-
sprung vehicles with a roll-off container, for example, compulsory lowering of the vehicle frame
must ensue when the power take-off is engaged.
Residual air bellows pressure regulation for NA function via PSM (code EM7/EM8/EM9)
TT_54_00_006704_SH
Procedure for retrofitting the residual air bellows pressure regulation via PSM:
• Retrofit relay circuit at PSM (A22) and GM (A7). Enable output X4 18/13 in the PSM with
NA.
• Additional parameterization for the given PTO equation of the PSM, to ensure that the en-
gine runs during the PTO operation:
PSM parameters
Parameter 150 "FCAN event" "YES"
Parameter 160 "Designation" "Engine speed"
Parameter 180 "Threshold value" "0"
• Activate residual air bellows pressure regulation in the HM

Select HM system in DAS
Parameterization
Level control parameter group
Set parameter 122 to active
Information
If there are no pressure sensors installed in the vehicle, these have to be retrofitted. In
addition, a pressure sensor calibration will need to be carried out.

27 Cargo Liftgate
0 Instructions
27 Cargo Liftgate
Instructions
Total time ...........................................................................................................................30 min
27.1 Cargo Liftgate Preinstallation
The participant can describe the scope of the cargo liftgate preinstallation
Cargo liftgate preinstallation in Atego2, Axor2 and Actros2/3
27.2 Cargo Liftgate
The participant can describe the functioning of the cargo liftgate preinstallation
Training room 20 min.

27 Cargo Liftgate
27 Cargo Liftgate (Participants)

The preinstallation for cargo liftgate (code E33) includes the starter lockout safety equipment
required by law. When the switch is pressed, the starter lockout is activated by an interruption
at terminal 50 and this enables the power supply to the cargo liftgate. When the switch is not
pressed, the cargo liftgate is secured from unauthorized usage by an interruption in the power
supply. The 7-pin socket plug for connecting the cargo liftgate is located at the frame end of
the vehicle. The wiring for the preinstallation for ATEGO2/AXOR2 corresponds to wiring dia-
gram PE5.40-W-2000G, for ACTROS to wiring diagram PE55.40-W-2000E.
Cargo liftgate switch TT_60_00_006705_FA
Preinstallation in the frame TT_60_00_006706_FA

27 Cargo Liftgate
27.2 Cargo Liftgate
27.2 Cargo Liftgate

Exercise 78 Detail from the wiring diagram for cargo liftgate PE 55.40-W-2000E
TT_88_00_006709_SH
A1 Additional fuse strip H14 Cargo liftgate indicator lamp
A3 Drive control (FR) S103 Cargo lift gate switch
A6 MR engine control P2 Instrument cluster (INS)
A7 Base module S1 Starter switch
A26 Diode holder X55 SV – cargo liftgate
A31 Additional relay bracket
Look at the signal path in the circuit diagram for the cargo liftgate and discuss the answers to
the questions in your group. What signals are switched when the switch for the cargo liftgate is
actuated?
Terminal 50 to the drive switch is interrupted

The power supply to the contact body of the cargo liftgate is activated.
Exercise 79 Under what conditions are the cargo liftgate indicator lamps in INS actuated?
when switch S103 is actuated

when cargo liftgate is open and S103 is not actuated

28 Conclusion
0 Instructions
28 Conclusion
Instructions
Final Test
Notes and performance of final test
Training room 45 min
28.1 Concluding Discussion

20 min.

28 Conclusion
28.1 Final Discussion
28.1 Final Discussion

NEBN-ME263 Trainer Preparation
Daily agenda

Daily agenda
Time Duration Section Title Learning objective/content/work form/method Media
Day 1
1 Orientation
8:15 10 1.1 Welcome Structured card questions Visualize statements with participants
8:25 20 Introduction Round Mutual familiarization
Partner interview with metaplan cards
8:45 5 Training Overview The participant can name the contents of
the comfort and passive safety training
Overview of comfort and passive safety
training
Interactive lecture
8:50 5 Game Rules Define common rules of the game Supplement pre-prepared flipchart
8:55 5 Training Schedule The participant can name the contents and Pre-prepared flipchart
the training agenda.
Training agenda
Interactive lecture
2 Model series overview
9:00 1 2.1 Overview Overview of Atego2, Axor2, Actros2/3
Interactive lecture

Daily agenda

9:01 9 2.2 Atego2/Axor2 The participant can understand the model
Model Designations designations
The participant can identify the vehicle by
means of the VIN
The participant can assign the workshop
literature to model designations
Get to know the model designations and
enumerate the differences from the
Atego1/Axor1 through to the
Atego2/Axor2
Interactive lecture
9:10 10 2.3 ACTROS Model The participant can understand the model
Designations designations
The participant can identify the vehicle by
means of the VIN
The participant can assign the workshop
literature to model designations
Get to know the model designations and
enumerate the differences from the Actros1
through to the Actros3
Interactive lecture

Daily agenda

3 Power Distributor
9:20 10 3.1 Power Distributor The participant can describe the task of the
power distributor
The participant can state the possible ex-
pansions
The participant can state the possible in-
stallation locations
The participant can describe the procedure
in jump starting
Actros3 power distributor
Interactive lecture
Presentation
9:30 10 3.2 Actros MP3 Battery The participant can describe the task of the
Sensor battery sensor.
The participant can state the display possi-
bilities in the Instrument.
Actros MP3 battery sensor
Interactive lecture
Presentation
9:40 10 3.3. Installation The participant can name the installation
Locations of Control locations for the control units
Units The participant can name the major CAN
bus systems
The participant can assign abbreviations
and terms to the network using the info
sheet
Installation locations of the Atego2, Axor2
and Actros2/3 control units
Interactive lecture
Presentation

Daily agenda

4 Practical Work 1
9:50 20 4.1 Atego2/Axor2 The participants can describe the power
Power Supply supply / voltage curve
Group 2 with Atego2
Exercises on the vehicle
10:10 30 Breakfast
10:40 20 4.2 Actros3 Voltage The participants can describe the power
Curve supply / voltage curve
Group 1 with Atego2
Exercises on the vehicle
11:00 10 4.3 Comparison of Comparison of practical exercises
Practical Exercises Interactive lecture
Presentation
5 Networking
11:10 10 5.1 ATEGO2/AXOR2 The participant can describe the networking
Networking of the Atego2/Axor2
Atego2/Axor2 networking
Interactive lecture
Presentation

Daily agenda

11:20 10 5.2 Networking in the The participant can name the major CAN
Actros bus systems.
The participant can understand the names
of the basic control units, abbreviations and
terms.
The participant can explain the concepts
"virtual control units" and "distributed func-
tions".
The participant can describe the networking
diagram.
The participant can name the major func-
tions of the KontAct control units.
Actros2/3 networking
Interactive lecture
Presentation
11:30 10 5.3 Diagnostic Socket The participant can name the installation
X13 locations for the diagnostic sockets
The participant can state the assignment of
the diagnostic sockets
Diagnostic socket assignment
Interactive lecture
Presentation

Daily agenda

11:40 50 5.4 CAN Fundamentals The participant can name the physical
properties of the various CAN bus systems.
The participant can understand the struc-
ture of a CAN message.
The participant can understand the CAN
priority.
The participant can describe the basic func-
tion of the LIN bus.
Neutral points and terminal points,
CAN bus systems,
LIN bus
Interactive lecture
Presentation
6 Practical Work 2
12:30 13 6.1 Networking Further details on the Atego2, Axor2 and
Actros networking
Exercises as individual work
Practical Exercises Interactive lecture
Presentation
12:45 60 Lunch
7 Practical Work 3
13:45 45 7.1 Emergency Limp- The participants can apply the acquired
home Concept in theoretical content in practical situations.
Actros3 Group exercise in 2 groups
Group 1 on emergency limp-home concept
in Actros3
Exercises at the vehicle / model

Daily agenda

14:30 15 Coffee
14:45 45 7.2 CAN Measurement The participants can apply the acquired
on the Model theoretical content in practical situations.
Group 2 on emergency limp-home concept
in Actros3
Exercises at the vehicle / model
Practical Exercises Training room/workshop
16:00 25 Summary of 1st Day Summarize what has been learned and
discuss any open questions

Daily agenda

Day 2
8 Instrument
8:15 5 Review of the 1st Clarify unanswered questions from the 1st
day, call-out questions
Day
Interactive lecture
Presentation
8:20 5 8.1 Instrument The participant can describe the features of
the Instruments
Comparison of the two Instrument variants
Interactive lecture
8:25 10 8.2 Instrument 2004 The participant can differentiate between
the two Instrument variants
The participant can perform practical work
on the Instrument
Overview of Standard Instrument and High-
Line Instrument
Interactive lecture
8:35 5 8.3 New ATEGO/AXOR The participant can state the basic features
Instrument of the new Instrument
Scope of modification of the INS 2004
compared with INS as of 12/2010
(New ATEGO/AXOR)
Interactive lecture

Daily agenda

8:40 10 8.4 Instrument 2008 The participant can name the tasks of the
INS 2008 and name the main features of
the INS 2008.
The participant can name the tasks and
possible functions of the sound module.
The participant can explain the tasks and
how to handle the multifunction steering
wheel.
The participant can understand how the
multifunction steering wheel is operated.
The participant can name the distribution
and settings of the driver information sys-
tem.
Changes to the INS2008 compared to the
INS2002
Sound module in the INS2008
Driver information system FIS
On-board diagnosis
Interactive lecture
Presentation
9 Practical Work 4
8:50 45 9.1 Driver Information The participants can apply the acquired
System FIS in the theoretical content in practical situations.
Actros3 Group work in 3 groups
Group 2 on parameterization of INS in the
Atego2/Axor2
Group 3 on steering wheel buttons at the
model
Workshop

Daily agenda

9:35 45 9.2 Parameterization of The participants can apply the acquired
INS in the theoretical content in practice.
Atego2/Axor2 Group work in 3 groups
Atego2/Axor2
The exercise is prepared with a 2004 in-
strument cluster.
For the new instrument cluster (as of
12/2010) various answers may not be
correct.
We recommend checking the answers with
the participants against the vehicle.
model
Workshop
10:20 30 Breakfast
10:50 45 9.3 Steering Wheel The participants can apply the acquired
Buttons at the theoretical content in practical situations.
Model Group work in 3 groups
model
Atego2/Axor2
Training room

Daily agenda

10 Base Module
11:50 5 10.1 Base Modules The participant can describe the features of
the base module types
Brief comparison of the two base module
types
Interactive lecture
Presentation
11:55 10 10.2 Atego2/Axor2 Base The participant can name the major func-
Module tions of the base module.
The participant can state the tasks of the
relays.
Tasks and functions
Interactive lecture
Presentation
12:05 15 10.3 Base Module in The participant can name the major func-
Actros tions of the base module.
The participant can state the tasks of the
relays.
The participant can name the different
variants of the base module.
The participant can name the different
functions of the base module.
Tasks and functions
Interactive lecture
Presentation

Daily agenda

12:20 30 10.4 Central Data The participant can state the advantages
Memory / Mirror and the design of the central data memory.
Memory The participant can use the functions of the
central data memory with the DAS.
Tasks and functions
Interactive lecture
Presentation
12:50 60 Lunch
11 Practical Work 5
13:50 60 11.1 Signal Flow Exercises as individual work in the training
room
14:50 15 Coffee
Practical Exercises
12 Trailer Socket
15:20 10 12.1 Trailer Socket The participant can explain the connection
of the trailer socket in the vehicle.
The participant can name the maximum
power consumption of the trailer lighting.
Pin assignment and current load
Interactive lecture
15:30 10 12.2 Cotel Interface The participant can describe the task of the
CoTel interface.
Cotel task
Interactive lecture

Daily agenda

15:40 40 12.3 Modular Switch The participant can describe the design and
Panel (MSF) the tasks of the modular switch panel.
The participant can name the main features
of the modular switch panel.
The participant can name the parts and
components of the modular switch panel.
The participant can state the special fea-
tures in reference to retrofitting.
General description of the modular switch
panel
Master, slave, load, and signal switch
16:20 10 Summary of 2nd Clarify unanswered questions from the 2nd

Day
Interactive lecture
Presentation

Daily agenda

Day 3
13 Practical Work 6
8:15 5 Review of 2nd day Clarify unanswered questions from the 2nd
Interactive lecture
Presentation
8:20 10 13.1 Modular Switch The participant can understand the retrofit-
Panel ting of switches in the modular switch
panel.
The participant can perform practical op-
erations on the modular switch panel.
The participant can perform a proper diag-
nosis at the modular switch panel.
Exercises as individual work in the training
room
8:30 5 14.1 Exterior Lights The participant can understand the actua-
ATEGO2 / AXOR2 tion of the exterior lights.
The participant can describe the modifica-
tions of the main headlamps.
Headlamps and repairs

Daily agenda

8:35 10 14.2 Actros Exterior The participant can describe the design of
Lights the main headlamps.
The participant can describe the design and
method of operation of the xenon head-
lamps.
The participant can state the design and the
operation of the gas discharge lamp.
The participant can state the safety regula-
tions and precautions for xenon headlamps.
Exterior lights: H7 and xenon
Interactive lecture
8:45 10 15.1 Bulb Failure Monitor The participant can describe the functioning
in the Atego2/Axor2 of the bulb failure monitor.
Voltage divider, Ohm's law, necessity of
operation amplifier
8:55 15 15.2 Bulb Failure Monitor The participant can describe the functioning
in the Actros of the bulb failure monitor.
Description of the bulb failure detection,
static/dynamic
Voltage divider, Ohm's law, necessity of
operation amplifier
Interactive lecture
Presentation

Daily agenda

16 Practical Work 7
9:10 20 16.1 Possibilities of Fault The participant can describe the fault de-
Detection by Control tection by control units.
Units Possibilities of fault detection by control
units
17 Door module
9:30 5 17.1 Door Control Panel The participant can name the design and
in ATEGO2/AXOR2 function of the controls in the doors.
Door control panel
Interactive lecture
9:35 15 17.2 Door Module in The participant can describe the design and
ACTROS function of the controls in the doors.
The participant can describe installation
locations, tasks and functions of the door
modules.
The participant can describe the theoretical

operation of the switch units in the doors.
General description and variants
Interactive lecture
9:50 30 Breakfast

Daily agenda

10:20 10 18.1 Rain/Light Sensor The participant can describe the design of
(RLS) the RLS.
The participant can describe the function of
the RLS.
The participant can describe the communi-
cation paths of the RLS.
General description of the RLS, design and
function of the rain sensor, design and
function of the light sensor
10:30 15 18.2 Function Pins The participant can state and understand
the connective logics.
AND, OR connectives
Interactive lecture
10:45 2 19.1 Battery Disconnect The participant can explain the notion of
Switch in GGVS GGVS (Regulations for the Transportation of
Hazardous Goods).
Vehicles (hazardous
goods vehicles)
10:47 10 19.2 Battery Disconnect The participant can state the special tech-
Switch in nical features and their functions in the
Atego2/Axor2 with GGVS equipment.
ATEGO2/AXOR2
Battery disconnect switch design and func-
tioning

Daily agenda

10:57 8 19.3 GGVS Functions in The participant can state the special tech-
the Actros nical features and their functions in the
Actros2/3 with GGVS equipment.
Battery disconnect switch design and func-
tioning
20 Antennas
11:05 5 20.1 Antennas The participant can name the installed
antennas.
Overview of antennas
21 Practical Work 8
11:10 45 21.1 Wiring Diagram The participants can apply the acquired
Exercise for GGVS theoretical content in practical situations.
Axor2 Group work in 3 groups:
Group 1 on wiring diagram exercise for
GGVS Axor2, theory
Group 2 troubleshooting in Axor2
Group 3 on parameter setting at function
pin 17 in Actros3
Training room/
Workshop

Daily agenda

11:55 45 21.2 Troubleshooting at The participants can apply the acquired
the Axor2 theoretical content in practical situations.
GGVS Axor2, theory
pin 17 in Actros3
Training room/
Workshop
12:40 60 Lunch
13:40 45 21.3 Parameter Setting The participants can apply the acquired
at Function Pin 17 theoretical content in practical situations.
GGVS Axor2, theory
pin 17 in Actros3
Training room/
Workshop
Practical Exercises
Training room/
Workshop
14:45 15 Coffee

Daily agenda

15:00 15 22.1 Notes on product The participant can state liability criteria
liability and risks of accidents as a result of retrofit-
ting.
Product liability
Interactive lecture
15:15 15 22.2 Rules of Conduct for The participant can state the basic rules of
Retrofit Work on conduct for protecting consumers, cable
routing, wired connections, power supply
Electrical
and indicator lamps when retrofitting the
Consumers vehicle.
Rules of conduct
Interactive lecture
15:30 5 22.3 Cable Passages The participant can describe the necessary
and different possibilities for sealing cable
passages.
Notes on the correct cable passages
Interactive lecture
15:35 10 22.4 Retrofitting Control The participant can state and justify the
Units necessary operations for retrofitting a con-
trol unit.
Procedure in retrofitting CU
Interactive lecture
15:45 10 22.6 Adapter Cable and The participant knows the schematic design
Y-cable of a Y-cable.
Manufacture Y-cable
Interactive lecture

Daily agenda

15:55 5 22.7 Retrofitting The participant knows the schematic cir-
Switches cuitry of load switches.
The participant knows the method of opera-
tion of the background illumination.
The participant knows the method of opera-
tion of the indicator lamps.
Design and retrofitting of switches
Interactive lecture
16:00 10 Summary of 3rd Day Clarify unanswered questions from the 2nd

Daily agenda

Day 4
23 Voltage Sources
8:15 10 Review of 3rd Day Clarify unanswered questions from the 3rd
Presentation, interactive lecture
8:25 5 23.1 Voltage Sources on The participant can name the different
the ATEGO2/AXOR2 voltage sources of consumers.
The participant can state the load limits of
the voltage sources.
The participant can state options and pre-
conditions for connecting large consumers.
Plug X7.1, battery terminal
8:30 5 23.2 Voltage Sources on The participant can name the different
the ACTROS2/3 voltage sources of consumers.
The participant can state options and pre-
conditions for connecting large consumers.
Plug X7, power distributor, battery terminal
8:35 10 23.3 Power Supply in The participant can state options and pre-
Trailer/Semitrailer conditions for connecting large consumers.
Greater than 10 A Trailer/ semitrailer above 10A

Daily agenda

8:45 5 23.4 12 V Voltage The participant can name the different
Converter voltage sources of consumers.
Atego2/ Axor2 and Actros2/3
8:50 15 23.5 Practical Work on The participants can apply the acquired
Voltage Converters theoretical content in practice.
Fuse protection and wiring

9:05 45 24.1 Power Take-off via The participant can recognize that the GM
Base Module is sufficient for the use of simple power
take-off equations.
The participant can name the potential
danger when parameterizing power take-off
equations.
Actros3
9:50 30 Breakfast
25 Practical Work 9
10:20 45 25.1 Retrofitting on The participants can apply the acquired
Actros3/Axor2 theoretical content in practical situations.
Training room pinboard

Daily agenda

11:05 45 25.2 Retrofitting the The participants can apply the acquired
Modular Switch theoretical content in practical situations.
Panel Group work in 3 groups
Training room model board
11:50 45 25.3 Power Take-off via The participants can apply the acquired
Base Module at the theoretical content in practical situations.
ACTROS3 Group work in 3 groups
on Actros3
12:35 60 Lunch
26 Compulsory Lowering and Residual Air Bellows Pressure Regulation

13:55 10 26.1 Compulsory The participant can describe the compul-
Lowering via Base sory lowering function.
Module Compulsory lowering for power take-off via
GM
Interactive lecture
14:05 10 26.2 Residual Air Bellows The participant can describe the residual air
Pressure Regulation bellows pressure regulation function.
via Base Module Residual air bellows pressure regulation
with power take-off via GM
Interactive lecture

Daily agenda

14:15 10 26.3 Compulsory The participant can describe the compul-
Lowering and sory lowering function with residual air
bellows pressure regulation via PSM.
Residual Air Bellows
Compulsory lowering and residual air bel-
Pressure Regulation lows pressure regulation for power take-off
via PSM via PSM
Interactive lecture
27 Cargo Liftgate
14:25 10 27.1 Cargo Liftgate The participant can describe the scope of
Preinstallation the cargo liftgate preinstallation
Cargo liftgate preinstallation in Atego2,
Axor2 and Actros2/3
Interactive lecture
14:35 20 27.2 Cargo Liftgate The participant can describe the func-
tioning of the cargo liftgate preinstalla-
tion
Training room
14:55 15 Coffee
28 Conclusion
15:10 45 Final Test Notes and performance of final test
Training room
15:55 20 28.1 Concluding Brief feedback
discussion

Daily agenda

1511 8410 - 1st edition 11.2.2011 218

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Global Training – The finest automotive learning

Trucks · Overall Vehicle - On-Board Electrical

© 2011 Copyright Daimler AG

Publisher: Global Training

1511 8410 - 1st edition 11.2.2011 218

2 Model Series Overview...............................................................................................3

3 Power Distributor .......................................................................................................7

4 Practical Work 1.......................................................................................................16

6 Practical Work 2.......................................................................................................36

7 Practical Work 3.......................................................................................................39

NEBN-ME263 <> Trainer Document I

9 Practical Work 4.......................................................................................................59

10 Base Module ............................................................................................................66

11 Practical Work 5.......................................................................................................74

13 Practical Work 6.......................................................................................................91

14 Exterior Lighting .......................................................................................................94

15 Exterior Lamp Failure Monitor................................................................................101

II NEBN-ME263 <> Trainer Document

15.1 Bulb Failure Monitor in the Atego2/Axor2........................................................................ 102

16 Practical work 7 .....................................................................................................105

17 Door Module ..........................................................................................................111

18 Rain/Light Sensor (RLS), Connective Logics .........................................................115

19 Battery Disconnect Switch.....................................................................................124

21 Practical Work 8.....................................................................................................135

22 Retrofitting Electrical Consumers ..........................................................................141

NEBN-ME263 <> Trainer Document III

23 Voltage Sources .....................................................................................................151

24 Power Take-off via Base Module ............................................................................162

25 Practical Work 9.....................................................................................................167

26 Compulsory Lowering and Residual Air Bellows Pressure regulation.....................176

27 Cargo Liftgate ........................................................................................................180

NEBN-ME263 Trainer Preparation ...............................................................................185

IV NEBN-ME263 <> Trainer Document

Structured card questions 10 min

Partner interview with metaplan cards 20 min.

Interactive lecture 5 min.

Interactive lecture 5 min.

NEBN-ME263 <> Trainer Document 1

2 NEBN-ME263 <> Trainer Document

2 Model Series Overview

Interactive lecture 1 min.

2.2 Atego2/Axor2 Model Designations

The participant can understand the model designations

2.3 Actros Model Designations

The participant can understand the model designations

NEBN-ME263 <> Trainer Document 3

2 Model Series Overview (Participants)

2.2 Atego2/Axor2 Model Designations

4 NEBN-ME263 <> Trainer Document

Sales designations ATEGO2 AXOR2

NEBN-ME263 <> Trainer Document 5

2.3 ACTROS Model Designations

Model plate N_58.00-002024-SW

The ACTROS2/3 cabs

6 NEBN-ME263 <> Trainer Document

3.1 Power Distributor

The participant can describe the task of the power distributor

Interactive lecture 10 min

3.2 Actros MP3 Battery Sensor

The participant can describe the task of the battery sensor.

Interactive lecture 10 min

3.3 Installation Locations of Control Units

Interactive lecture 10 min