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® Mercedes-Benz

Operating Instructions

,.1 1013 1413

C 1QiV 1417
1213 1613
1217 1617
Contents

Page Page
Componenls .................... . ... .....•. 6 Vehicle service and maintenance . ....... . ....... . . 58
1.1 Door control . 6 Veh ic le lools and emergency equlpement . 5.
1.2 Seal adjustment . 7
13 Instruments - summary. . . .. .... ..• . 8 ' .1 Tilting cab . 60
1 .. Indicator lights and switches. 10
1.5 Instrument cluster..................• 12 4.1.1 Tilling th e cab. 60
1.6 Tachometer . 12 4.1.2 Lubricating tilti ng c ab bearings . 61
1.7 Tachograph . 12
1.8 Battery maste switch 13
' .2 Engine .

""6364
1.' Steering lock. 13
1.10 4.2.1 Oil and filter change.
1. 11
1.12
Switch bOX
Light swi tch
Combina tion switch.
"1414 4.2.2
4.2.3
Inspecting and servicing paper air cleaner .
Servicing the oil bath type air cleaner.
1.13 Controls for window and exterior mirror 15 4.2.4 Servicing dust separating valve. 54
1.14 Sun visors . 15 4.2.5 Removal and installation 01 cylinder head cover. 65
US Saat belt . 16 4.2.6 Tightening cylinder head bolts. 65
1.16 Assistant driver's seat 4.2.7 Adjusting valve cl earan ce

""
16
1.17
1.18
Steering wheel adjustment .
Control valves .
16
17
4.2.8 Lubricating Ilywhee l ring gear. .......... . .
1.19 Heating and ventilation ........... •. 18
1.20 Seal heater. 18 ' .3 Fuel system . 67
1.21 Supplementary heater . 20 4.3.1 Cleaning of fuel tank .. . ... . ... 67
1.22 Rad io . ................. . . .. • . 22 4.3.2 Check and clean fuel precleaner 67
1.23 Handling 01 bunks ..... . ........... .• . 24 4.3.3 Renewal of luel IiIler elements ... 68
Guard on bumper .. 4.3.4 Cleaning the lell filter elements.
1,24
1.25
1.26
Opening the front panel. ...... .. . .• .......... . .. • .
Opening the front flap .
"
27
27
4.3.5
4.3.6
Bleeding the luel system.
Injection nozzles .
6.
6.
6.

2 Operation ..
2.1 Preparations for driving .... ................. . . . "" •••
4.4.1
Cooling system ................
Draining coolant and Iilling system with coo lant
70
70
2.2 Starting and shutting olf the engine ..... ......• • 35 4.4.2 Cleaning cooling and healing systems . 71
2.3 Hand brake operation 37 4.4.3 Fan with fluid coupling .
2.4
2.5
Starting the veh ic le and sh ift ing gears ..
Breaking·in . .,
38 4.4.4 V·belts .
71
71

.
4.4.5 Checking thermostatic switch and buzzer . 73
2.6 Oriving and braking ................... ... . . 42
2.7 Trailer and semftrailer . 47
2.B Dump truck operation . '.5 Clutch . 74
2.9 Air suspension .. . ... ................. ... .•. 50
2.10 Winter operation. 51 4.5.1 lubricating clutch release be aring sleeve . .... .... . . 74
4.5.2 Bleeding hydraulic clutch control system 74
3 Fuels, coolants, lu bri cants, etc. 55
3.1 Diesel luels . 55 '.6 Transmission . 75
3.2 Engine oils .
3.3 Coolant . "
57
4.6.1
4.6.2
Oil level ch eck and oil change .
Cleaning bre ather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
77

4
 Page Page
'.7 Live fro nt axle . 78 4.13 Chassis . 101
4.7.1 Oil level check and 011 change ....... • . . 78 4.13.1 Checking and servicing the traiter coupl ing .. 101
4.7.2 Ring gear adjusting screw . . 78 4.13.2 Checking and servic ing the fifth whee l coupling . 101
4.7.3 Cleaning breather . 78
4.14 Vehicle cleaning and care . 102
'.8 Rear axle 79 4.15 Preparing the vehicle lor stor age . 103
4.8.1 Oil level check and oil change .......... _•. 79 4.16 Preparing the vehicle lor service alter stora ge . 103
4.8.2 Cleaning breather. 80
4.B.3 Ring gear adj ustment screw (H L 4). 80
5 Troubleshootin g . 104
•••
4 .9.1
Sleerlng. . . . . ........ . .. . ....... •
Checking the steering linkage.
B1
B1
5.1
5.2
Engine and fue l system .
Clutch .
10.
105
4.9.2 Oil level chek and oil change .. . . ....... .•. B1 5.3 Steering . 106
4.9.3 Checking the toe-in .. 82 5.4 Brake system. 106
5.5 Electrical system . 108
4.10 Wheels and lires . 83 5.6 Supplementary heater. 10.
5.7 Maneuvering and towing . 110
4.10.1 Spare wheel location . 83
4.10.2 Wheel change . . ..... . ... . . 84
4.10.3 Tire inflation connection .. . . .... • . 85 6 Technica l Data . 112
4.10.4 Tire change . 85 6.1 Data cards/identification plates. 112
6.2 Engine . 113
4.11 Bra ke sys tem . 86
4.11.1
4.11 .2
Checking the brake lines .
lubrication of exhaust brake linkage ..... . ... . . • .
86
86
6.3
6.4
6.5
Cooling system .
Clutch .
Transmission .
"'
114
114
4.11 .3
4.11.4
4.11.5
Checking the brake linings .
Checking service brake adjustment .
Adjust ing the service b rake .
. . ............. .
.7.7
87 6.6
6.7
6.8
Transler case
Steering system
Front axles ... . ... . . . . . •
116
116
117
4.11.6 Adj usting the brakes . as 6.9 Rear axles .. . ........ .. . 119
4.11.7
4.11.8
Checking automatic slack adjusters ..
Adjustment of hand brake . •••• 6.10
6.11
Air suspension .
Brake system.
122
124
4.11.9 Releasing spring-loaded brake cylinder with 6.12 Electrical system ......... . .. . . • 131
depressuri zed compressed-a ir system . 91
4.11 .10 Hydraulic clutch and brake control sys te ms - check flu id level . 93
7 Tightening torques - summary ...... . ... • . 144
4.11 .11 Bleeding hydrau lic brake con trol system . 93
4.11 .12 Hydraulik brake sys te m - c hecking f luid level .. 94
4.11 .13 Bleeding the brake system . 95

4.12 Electrical system . ,. Capacities _ summary .

Service and maintenance jobs - summary.

146

148
4.12.1 Curren t collection on 24 V systems . 96
4.12.2 Checking the headlight setting. 96
4.12.3 Replacing bulb in headlight and in turn signat tight. 96 Lubri ca tion points - summary . 149
4.12.4 Three· phase alternator . 97
4.12.5 Fuses .. 97
4.12.6 Batlery care. 100 Tire prassura chart

5
1 Components 1.1 Door control

Door control, outs ide Door and win dow co ntrol, inside
Unlocked Door latch unl ocked
To open the door, press in door lock 2 Door latch locked
cylinder
3 Opening lever
2 Locked (to open the door, swing lever up)
4 Window crank
5 Vent window lock
(pus h button to unlock)

6
1.2 Seat adju s tm e nt

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.... -r"".. .
.: .. "·,,Y...·.::';":.
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=---=-===:... -::.::- .

Standard vers ion Seat load Air-sprung seat (examp le)

1 Fo rward and backwa rd adjustment 2 Scale for seat load (example)
2 Heig ht of seat , front portion 3 Seat spring lock
3 Height of seat, rear portion Impose load an seat and pull lever
4 Seat back position upwards = spring lock is engaged.
Impose load on seat and push Jever
. down = spring lock is released.
1 Seat spring lock
Impose load on seat and pull lever
upwards = sp ring Jock is engaged.
Impose load on seat and push lever
down = spring lock is re leased.

7
1.3 Instru me nts - summary

Ventilation and defrosting elements for side win dows. 11 Fresh air louver (page 18)
adjustable (page 18) 12 Cover - fuse box (page 98)
2 Maintenance indicator, paper air cleaner Oddments shelf
13
(pag es 33 and 63) (other oddments trays above windshieJd)
3 Tachograph or speedometer (page 12) Knob, idle speed increase (page 35)
14
4 Indicator lights (page 10) 15 Air pump , "Start-Pilot " (page 53)
5 Tachometer (page 12) Actuation of radiator shutter (page 38)
16
6 Instrument cluster (page 12) Combination switch (page 14)
17
7 Switches (page 10) 18 Plug socket
8 Heating and ventilation (page 18) Knob, fresh air to footwell (page 18)
19
9 Vent ilation and defrosting elements , adjustable (page18 ) Foot pump , windshield washer system
20
10 Ashtray 21 Release handle, front end pane l (page 27)

8
9
1.4 I ndicator lights and swi tch es
The il lustration depicts the symbo ls the indicator lights an switches are marked with.

Indicat or lights 9 Turn signal indicator light - tractor

Cab lock (page 30) 10 High beam indicator light

11 Turn signal i.ndicator light - trailer/sem itrailer
2 Differential lock, live front axle (page 17 and 40)
12 Hand brake re lease contro l (page 37)
Differential lock, 1st rear axle 13 Brake fluid (brake system) and brake pad wear (page 46)
14 Gearsh ift range se lection
Differential lock, rear axle (page 17 and 40)
speed range R, C, 151 to 4t h gear (page 39)
4 Differential lock, 2nd rear axle
15 Gearshift range selection
5 Power take-off (pages 17 and 41) speed range 5th to 8th gear (page 39)
6 Dump body assembly (page 49) 16 Differential lock, transfer case (page 17 and 41)
7 Warning light - hydraulic brake system
(page 45)
17 I-MI Differential lock, power divider
8 Charge indicator light (page 46) l'erbl Oil level warning light - engine (page 45)
18 Tire puncture feeler
Switches
19 Hazard warning flasher switch with indicator light 27 Window control, ass istant driver's door (page 15)
20 Dimmer switch fo r instrument lighting 28 Cont ro l for RH exterior mirror (page 15)
21 Seat heater left with indicator light (page 19) 29 Fog lights with indicator light
22 Seat heater right with indicator light (page 19) 30 Rear fog light with indicator fight
23 Rotary flashing beacon with indicator light 31 Heated outside mirror with indicator light
24 Refrigerator with indicator light 32 Vehicles without steering lock = switch box (page 14)
Vehicles with steering lock = light switch (page 14)
25 Lift axle with indicator light
33 Starter push button (vehicles without steering lock)
26 Air horn with indicator light

10
(t)
33

11
1.5 Instrument cluster 1.6 Tachometer (example) 1.7 Tachograph (example)

Brake pressure warning light 1 Optimum economy range 1 Time group knob
2 Duplex pressure gauge 2 Economy range 2 Speedometer
1st pointer = supply pressure 3 Ra1ed speed (full load - max. speed) 3 Speed warning light
1st brake circuit
4 Governed speed range (avoid hazard 4 Clock function control light
2nd pO inter = supply pressure
warn ing range, if possible) 5 Function control light
2nd brake circuit
5 Overrevving speed (dangerous range)
3 Coo lant temperature gauge
6 Maintenance indicator
4 Oil pressure gauge
(1 unit corresponds to 1000
5 Fuel gauge crankshaft revolutions)
Warning buzzer in cab
Caution: The buzzer sounds if
1. the coolant temperature is too high,
2. the coo lant level is too low (vehicles with coolant expansion tank located below the
cab).

12
1.8 B attery master s witch 1.9 Steering lock
. ~.

'
": :
..

,.
~
'
.. .
. -~

Minimum supply pressure in the com-
pressed-air system is 7 bars (99.5 psi ).
Control valve on the instru ment panel
Actuate control valve until the battery
master switch changes over.
Pu l l == switch i ng on
Push == switching off
The con trol valve returns to center
position.
Battery maste r switch on battery box
Parallel to driving di rection = switch-
ed on
All consuming units can be switched
on.
Transve rse to driving direction =
switched oft
All consuming units are disconnected
fro m the battery.
The actuation lever can be pulled off.
In this position the key can be inserted
or removed. When the key is with-
drawn , th e steering is rocked.
2 Driving position = steering un locked.
3 Turn key to stop = starte r engaged .
Caution:
The key is locked if
- the engine is operating
- th e battery master sw itch is switched
off
- the electrical system has failed
Never lock' the steeri ng if
- the vehicle is roll ing
- the engine is operating but the genera-
tor is faulty (charge indi cato r light co-
mes on )

13
1.10 Swi tch box 1.11 Light switch 1.12 Combination switch
Vehicles with st"erine lock

.
o

Switch box key removed or steering lock Switch box key inserted or steering lock
locked in drivin g position .
Switc h box or li ght switch in: Switch box or light switch in:
Switching position "0": Switchi ng position "0", "1", "2" in addi-
Plug socket, interior l igh t, hazard tion :
warning flasher system supplementa ry Fuel ga uge
heater brake pressure warning light,
Switching position " 1" in addition : turn signal lights,
Instrument ligh ting, parking light, tai l sto p lights,
lights, clearance lights, fog lights indicator ligh ts,
windshield wiper,
Switch i ng position " 2" in addition:
heater b lower,
High beam . Iow beam, high beam
buzzer,
indicator light
horn,
sta rter
1 Low beam
2 High beam
3 Headli ght fla sh er
4 Turn signal lights, right
Up to point of resistance = brief flash·
ing. Beyond point of resistance (en-
gagemen t) = continuous flash i ng
5 Turn signal li gh ts, left
Up to poin t o f resistance = brief flash ·
ing. Beyond point o f resistan ce (en-
gagement) = con tinuous flash ing
6 Horn
7 Windshield w iper
Press switch = on
Press switch once mo re = off

14
 1.13 Controls for window and 1.14 Sun visors (example)
exterior mirror (example)

8 Windshield wiper Rocker switch - w indow control 1 Ad justable downwards/upwards

Rocker switch Press upper end to close 2 Adj ustable upwards/downwards
"I" Center posit ion = low speed Press (ower end to open and fore/aft.
"11" Press right end = high speed 2 Rocker switch - exterior mirror con-
"Il l " Press left end = intermittent trol
wip ing (inde pendent of position Press upper end = mirror moves to the
of switch number 7) le ft
9 Windshield washe r headlight Press lower end = mirror moves to the
washer right
Turn switch = switched on
The headlight washer (optional) is
only operated when the vehicle lights
are switched on.
Check wiper blades regularly fo r soil -
ing and damage.

15
1.15 Seat belt (example) 1.16 Assistant driver's seat 1.17 Ste ering wheel adjustment
Long cab

Fastening:
1 Pull belt with tongue (1) over shoulder
and lap. The bel t m ust not be twisted
but must be tight
2 Press tongue (1) into buckle (2) and al-
low to engage audibly
Unfastening:
1 Depress red button in buckle (3)
Unlock (ti lt assistant driver's seat for-
ward, be sure to lock after tilting seat
back)
2 Arm rest height adjustment
Height and inclination of t he steering
w heel are adjustable
1 Clamping screw - vertical
adjustment
2 Clamping screw - horizontal
adjustment
Tighten clamping screws afte r the ad-
justment of the steering wheel.

2 Return tongu e (1) to initial position

Note:
The intertia reel of the seat belt stops
the belt unwinding further in case of ve-
hicle deceleration in any direction and if
the belt is putted out quicJy.

16
1.1 8 Control valves

r-
'4

t
"
f;
,
L
D7 •
....2
2

Differential lock (inter-wheel )

7~
4 Power take-off I
Rear axle 5 Power take-off II
2 Differential lock (i nter-wheel) 6 Reserved for optional extras
Live front axle Transfer case
VG 500-3 W
3 Differential lock (inter axle)

~
Transfer case

Power take-off
NA 3/60 - 11

17
1 ..19 Heating and ventilation

Control levers and switches are infinitely Lever positions: down = closed 7 Ventilation and defrosting nozzles,
variable up = open adjustable
4 Ventilation or heating of footwell 8 Ventilation and defrosting nozzles,
Blower sw itch
Lever positions: down = open adjustab le
Lever positions; down = off
up = on
up = closed 9 Knob for footwell venti lation
5 Lever for fresh air flap left = open
2 Heater control valve
Lever positions: down = hot Lever positions; down = open right = closed
up = cold up = closed 10 Fresh air nozzle/heater nozzle
3 Ventilation and defrosting of wind- 6 Fresh air louver swings sideways, up 11 Heater nozzles
shield and side window and down

18
Setting examples: 1.20 Seat heater
Lever position for window defrosting
(supplementary heater control valve lever
up)
1 = up
2 = down
3 = up
4 = up
5 = up

Turn nozz les 7 and 8 towards window

Defrosting is facilitated by slightly
opening the vent windows

Lever positions with heater fully on

(supplementary heater control valve lever
up)
1 "" up Control switch
2 = down
Press upper end (.. ) fast heating
3 = up
Press lower end (.) continuous operation
4 = down
Center position off
5 = up
When the seat heater is switched on, the indicator in the switch lights up.
Lever pOSitions wi th ventilation fully on If the engine is off, do not engage position "fast heating" for longer than is absolutely
1 = up necessary.
2 = up
3 = up
4"" down
5 = down
9 = turned left
Open air flap in roof

19
1.21 Supplementary heater
The supplementary heater can be operated with the vehicle
engine stationary or in operation.
Note: Switch on supplementary heater for approx. 5 minutes at
least once a month.
To heat cab interi or and preheat engine,
switch on battery master switch (optional)
push heater control valve lever all the way down
push supplementary heater control valve lever up or down
up = heating cab interior
down = heating cab i nterior and preheating engine
switch on blower
set air distribution as desired
- switch on supplementary heater.
Preheat engine,
switch on battery master switch (optional)
push heater control valve lever all the way down
push supplementary heater contro l valve lever down
switch on supplementary heater.
The combustion process starts after approximately 15 sec-
onds. At a coolant temperature of approximately 78° C the
process is automatically interrupted and started again at
approximately 73° C.
Caution:
Switch off supplementary heater before the lever of the control
valve for heater push upwards.
20
Note! The heater is automatically switched off after an approx-
imately 2% minute lag .
Timer, supplementary heater
Time recall
Press switch 1, the time is ind icated in inspection window 8.
By additionally pressing switches 4 or 5 the time may be
corrected.
2 Programmed heating
Switching on:
Recall time and correct if necessary. Press switch 2. The
indicator light " Preselection " lights up and the last preselec-
tion time set appears for approximately 20 seconds in the
inspection window. While the preselection t ime is being indi-
cated the desired new preselection time can be set by pushing
switches 4 or 5. By simu ltaneously pus hing swit ches 4 and 5
the time display jumps to 00:00. This permits a shortening of
the setting process.
The heater switches itself on au tomatically at the preseiected
time. The indicator light 7 "Supplementary heater" tigh ts up.
Switching off :
The supplementary heater can be manually switched off by
pressing switch 2. The indicator lights go out. After a maximum
of 1 hour the supplementary heater switches off automatically.
 r~--~----------------~'

lever, control valve Timer , supplementary heater

supplementary heater (examp le)
1 Heating cab interior
2 Heat ing cab interior and preheating
engine
Time recall 5 Time adjustment (fast)
2 Programmed heating 6 Indicator light, preselectio n
3 Immediate heating 7 Indicator light, supplemen tary heater
4 Time adjustment (slow) 8 Window , time readou t

3 Immediate heating
Switc hing on:
Press switch 3. The indicator light "Supp lementary heater"
llghts up. The supplementary heater operating time remai ning
is shown in the inspection window (max . 1 hour). By pressing
switched 4 and 5 this can be sho rtened.
Sw itching off:
By pressing swi tch 3 the supplemen tary heater can be
switched off manually. The indicator light goes out.
After a maximum of 1 hour the supp leme ntary heater switches
off automatically.

21
1.22 Radio
1 On·Off/Volume control
2 Tone control
3 Push buttons for band selection and tuning of preset
stations
4 Manual tuning control
5 Cassette eject
6 Fast forward
7 Fast rewind
".) 8 Cassette slot
Rad io with push buttons for tuning of preset stations 9 Wave band indicator

. ,
Radio with pus h buttons for tun ing of preset stations and with
built·in cassette player

22
On~OffNolume control
Turn knob (1) clockwise to switch on radio and to increase
volume. The green control lamp will come on.
Tone
Tu rn lever (2) to al ter the tone.
Station Tuning
Select desired wave band by pushing the respective button (3).
The wave band selected is indicate d by wave band indicator
(9). The desired station is tuned in by turning the manual tun ing
knob (4). For good reception, accurate manual tuning is
important.
To preset stations of va ri ous wave bands, pull out preset button
(3) to the stop, tune in station with manua l tu ning knob (4) and
push preset button in again to the stop.
Tape Playback
On ly use brand C 60 or C 90 cassettes . Push cassette into cas-
sette slot as far as it will go with the full reel on the right side.
The radio will then switch over from radio reception to tape
playback. The cassette wi ll be released automaticall y as soon
as the tape reaches its end.
To play the other side of the tape , turn cassette upside down
and reinsert it into cassette slot.
To manua lly eject the cassette, push release bar (5). When the
cassette is ejected, the unit will switch over to radio reception
automatically. .
Push button 6 or 7 for fast forward or rewind of the tape. Briefly
touching the counteracting button will stop th e winding pro~
cess.
Care and Maintenance
Since depOSits on the pick~up head are inevitable after extend-
ed operation, the cassette should be cleaned with a cleaning
cassette if the quality of the sound reproduction declines. After
approx. 500 operating hours the unit should be inspected by a
specialist.
23
1.23 Handling 01 bunks

Vehicle s with med ium· length cab

Upper bunk folded up, secured FOld up lower bunk Lower bunk folded up, secured
- Do not set off unless the upper bunk - Do not slide back assistant driver 's seat
has been fo lded up and secured with as long as the lower bunk is not fo lded
two straps. up and secured with a re ta ining strap.

24
Vehicles with long cab

Folding down RH upper bunk section:

- Disengage upper nel (1 and 6) and
engage into brackets (2 and 8) in rear
wall.
- Disengage lower net (1 0, 17, 16and21).
Lift up bracket (18) and swing forward.
- Push locking bolt (12) rearward and
slide outward to stop.
- Press lock in support arm (11) ou tward
while slightly l ifting the bunk. Continue
lifting the bunk and swing support arm
rearward.
Fold down bunk and engage into
brackel (18).

To l ift the bunk, loosen lock (7) while

pressing t he bunk slightly rearward.

To prepare the bunk for use, proceed in

reverse sequence.

Folding down LH upper bunk section:

- Open retaining straps of the upper net
at the support strap (3) and disengage
nel (1 , 6, 5 and 9).
- Disengage support straps (13 and 14).
- Disengage support straps (3 and 4).
- Press lock in support arm (15) ou tward
while slightly lifting the bunk. Continue
lifting the bunk and swing support arm
rearward .
To prepare the bunk for use, proceed in
reverse sequence.
Lifting the lower bunk :
- Slight ly press bunk downward and pull
oul knob (1 9)
- Lift bunk and engage support strap
(20).

25
1.24 Guard on bumper

Lower guard: 2 Catch hook Swi ng up guard :

- prio r to opening the maintenance flaps Push back guard slightly, disengage - after having returned the cab to driving
(front panel and front flap) safety bow from catch hook and lower position
- prio r to tilting the cab guard. - after having closed the maintenance
flaps
Unlock safety pi ns
Swin g up gua rd until the safety pins en-
Insert pump lever (on-vehicle too ls)
into guide t ube and pull down until the
gage audibly.
guard is retai ned by the catch hook.
Remove pump lever.

26
1.25 Op ening the front panel 1.26 Opening the front fl ap
~

Actuate hand lever 2 Actuate safety catc h Actuate locking spring

The front panel opens to the stop of First push back the front panel slight- Open front panel beforehand
the safety catch. ly, disengage safety catch and swing
fo rward front panel.

27
 2 Operation

2.1 Preparations for driving

Check the following items daily

- Accessibility and completeness of the emergency equipment, e. g. first aid kit, hazard
warning triangle, fire extingu isher

Prior to starting the engine

- Fuel reserve
- Vehicle lighting, turn signal and stop lights
- Oil level in engine
Fuel tank (example) - Trai le r coupling and fifth wheel coupling
- Compressed-air storage tanks - drainage of condensation
- Cab locking device

After having started the engine

- Engine oil pressure

- Steering free play
- Supp ly pressure in the compressed -air system
- Funktion test - tachograf

Fuel reserve

Insert switch box key or turn steering lock to driving position . Check fuel level on fuel
gauge in instrument cluster. Refuel, if required. Before refuelling, shut off eng ine and
supplementary heater. For summer and winter operation veh icle diesel fuels see
"Fuels, coolants, lubricants, etc."

28
Vehicle lighting, turn signal and stop lights

The lighting system inclusive of the stop lights must be checked daily for good condi-
tion and clean lenses. If bulbs have to be replaced , observe the specified vo ltages. Refer
to "Technical Data".

Oil level in engine

Vehicle has to be on level ground when oil level in o il sump is checked. Oi l level to be
somewhere between the lower and upper mark on the oil dipstick. Oil level should not
exceed the upper mark.
Caution: Use on ly engine oils of specified SAE grades (viscosity range). Refer to" Fuels,
coolants, lubricants, etc.".

Trailer co upling and fifth wheel coupling

Wi th regard to roadworthiness. the trailer and fifth wheel couplings are among the most
important parts of the vehicle. For their handling, care and maintenance refer to manu-
facturer's instructions.
The trailer coupling should be checked daily for longitudinal play. Firmly move coup l ing
unit back and forth. Do not grip the coupling jaw. Long itudinal play must not be tolera-
ted and shou ld be eliminated immediately. It could result in the breakaway of the trailer.

29
 Compressed-air storage tanks - drainage of condensation

During the co ld season condensation must be drained daily from the compressed-air
storage tanks.
Pull or push drain valves.
If the drain valves are clogged, remove valves and clean or renew. Caution: Relieve
compressed ai r before removing the drain valves , e.g. by actuating the service brake
several times.

Cab locking device

The cab must be completely tilted back and locked. In short cabs, check the locking
Compressed-air storage tank mechanisms behind the driver's and the assistant driver's seat, in long cabs, check the
Draini ng condensation
position of the safety lever behind the driver's seat.

I Engine oil pressure

I
j
The oil pressure in an engine running at operating temperature and full speed may drop

" .~
to 2.5 bars (35.5 psi ) and at idle speed to 0.5 bars (7.1 ps i). This will not impair the opera-
tional reliabi l ity of the engine.

-J

i'-'i
~ ~
Steering free play

Manual steering
Cab locking device - short cab
1 Locked } As soon as signs of play in the steering are apparent, have the steering checked in a
2 Unlocked Pu mp lever (veh icle to ol kit)
MERCEDES-BENZ service station.

30
Power steering
Play in the steering should only be checked when the engine is running.
Thewheels muststart moving when the steering wheel is turned approx. 30 mm (1.2 in).
If they do not move, have steering gear and linkage inspected by a MERCEDES-BENZ
service station.

Supply pressure in the compressed-air system

The supply pressure in the compressed-air system must be at least 5.5 bars (78 psi).
The brake pressure warning light must not come on .
Cutout pressure ist 8.1 bars (115 psi).
Cab locking device _ long cab
1 Locked
2 Unlocked

Tachograph function control light

The contrellight comes on:

it no chart is inserted,
if the tachograph is defective,
- if the tachograph is opened.

1 Tachograph function control tight

31
 Check at regular intervals:
(for example once a week or whenever you refuel)
Coolant level
- Antifreeze unit - fluid level
Power steering - oil level
- Soiling of air cleaner
Batteries - fluid level
~-
,- Windshield washer system - fluid level
Inflation pressure and condition of tires
- Hydraulic clutch and brake control systems, hydraulic brake system - fl uid level
- Seat belts
Compressed-air brake system for leaks
Coolant expansion tank (example)
1 Filler hole Engine, transmission, live axles, steering system, cooling and heating systems for
leaks

Coolant level

Only open fille r cap at coolant temperatures of less than 90" C/194" F. The expansion
tank must be filled to the brim of the fille r neck.
If possible , replenish coolant only with the engine cold (coolant temperature less than
122" F/50° C) and the heater valves open. Use clean and well filtered water (potable
water quality) with the least possible content of calcium and blend with anticorrosionl
antifreeze agent and treating agent. Refer to section 3.3.
Install expansion tank filter cap. Run engine for a short while. Check coolant level and
replenish, if requ ired.

Antifreeze unit - fluid level

Cab !Hted forward
Coolant expansion tank (example) During the cold season the fluid reservoir must always contain sufficient methylated
1 Filler hole spirit. Refer to " Winter operation".

32
Powe r steering - oil level

In the running engine the oil level must reach the upper dipstick marking, in the
stationary engine approx. 1-2 cm/0.4-0.8 in above this marking.

Soiling of air c l ea n ~r

Paper air cleaner

Engine 352
Run the warmed-up engine at full throttle (accelerator fuJly depressed) and observe
maintenance indicator. If the red field engages, clean or renew filter element.

Engine 352 A
If the enti re red field becomes visible in the maintenance indicator, clean or renew filter
element. Front end panel opened (example)
Power steering oil reservo ir
1 Filler hole
Oil bath type air cleaner 2 Oil level dipstick
Check the oH level of the air cleaner reg ularly. In the event of large amounts of dust en-
•.If' ·
tering the air cleaner, such a check should be performed once a week, in extreme cases
daily checks are required.
\V

Batteries - fl uid level

The batteri es are located on the side of the chassis frame.
The electrolyte level in each cell must be approx. 15 mm (0 .6 in) above the upper edge of
the plate . Only replenish with distilled water. During the hot season, check battery elec-
trolyte level more frequently.

Windshi eld was h er sy stem - fl uid level

The windshield washer reservoir is accessible after opening the front end panel. Add Front end panel opened
MERCEDES-BENZ windshield washer detergent at the water. 1 Reservoir, windshield washer system

33
 Inflation pressure and condition of tires

Check inflation pressure on cold tires. The pressure differential of the tires on one axle
must not exceed 0.1 bar (1.4 psi). High speed operation or hot weather may increase the
tire inflation pressure as much as 1 bar (14.5 psi). Never bleed any air as the pressure will
otherwise drop below specifications.
Caution :
The tyre inflati on pressure changes by approx. 0.2 bar (2.8 psi) whenever the ambient
air changes by 100 C (18 0 F). This must be kept in mind when checking the inflation
pressure in a room of different ambient temperature, particularly during the cold
season.

Example:
Room temperature = approx. + 200 C (+68 0 F)
Outside tempe rat ure = approx. 00 C (+3 20 F)
Inflation pressure to be set = specified tyre pressure +0.4 bar (5.7 psi).
For tires and in flation pressure refer to " Tire pressure chart."

Hydraulic clutch and brake control systems, hydraulic brake system - fluid level

The translucent reservoirs are located;

- behind the front flap
- on the master brake cylinder
The fluid level can be determined without unscrewing the cap. The reservoirs must
always be fi lled sufficiently. If brake fluid needs to be replenished, have the hydraulic
system inspected.

Seat belts

The inertia reel must stop the seat belt unwinding further if the vehicle
- is braked or accelerated
- is cornering
Master brake cylinder - or when the belt is pulled out qui ck ly.
Battery cover detached
1 Reservoirs - brake fluid Inspect belts visually for damage. Renew damaged seat belts.

34
Compressed-air br ake syste m for leaks
1. Run engine until the governor cuts out.
Coutout pressure 8.1 bar (115 psi). Shut off engine.
2. The system can be considered leakproof jf the drop in pressure is no more than 0.1
bar (1.4 psi) after a period of 10 minutes.
3. To test valves and brake cylinders for leaks, depress brake pedal partially (about 1/2
pedal travel or medium pressure exerted on brake-pedal). Observe duplex pressure
gauge. While maintaining a constant pressure on the brake pedal the indicators must
not show a visi ble drop in pressure within a period of 3 minutes.

2.2 Starting and shutting off the engine

Adhere to specific measures before starting an eng i ne for the first time after it has been
laid up fo r an extended period. Refer to "Preparing the vehicle for service after
storage ".
To facilitate starting at ambient temperatures below + 5" F (- 15" C), the vehicle can be
equipped with a "S tart-Pilot". Refer to "Wi nter operation".
Start the engine only with the transmission in neutral position .
Before starting, switch on battery master switch (opt ional).
Vehicles without steering lock:
Inse rt switch box key. The charge indicator light comes on.
Vehicles with steering lock:
Insert key in steering lock and turn to drivin g position. The charge indicator light comes
on.
Start engine with starter pushbutton or steering lock key without stepping on the accel-
erator. Should the eng i ne fail to start within approximate ly 5 seconds, depress accel-
erator slowly. If necessary, stop the procedure after max. 20 seconds and resume after
about 1 minute.
After three starting attempts, wait for at least 15 minutes before t rying again.
35
 Vehicles with steering lock:
Before starting again , return key to the stop.
After the engine has started, re lease starter pushbutton or steering lock key ease off ac-
celerator and adj ust idle speed. Observe oil pressure gauge immediately after starti ng.
The engine must be stopped immediately if no oil pressure is indicated.
Shut off the engine by depressing the floor button of the exhaust brake in front of the
driver's seat.
Caution:
Move gearshift leve r to the neutral position
The engine should never be shut off at a coolant temperature above normal (in excess of
+ 1940 F [+ 900 Cl), e.g. after operation in mountainous areas. but should be allowed to
idle for about alJothe r 1 to 2 minutes.

Cab tilted forward

1 Starter push button on englna

Starting and shutting off the engine with the cab tilted

Before tilting the cab.

Vehicles without steering lock:
Insert switch box key. The charge indicator light comes on.
Vehicles with steering lock:
Insert key in steering lock and turn to driving posit ion. The charge i ndicator light comes
on.
Tilting the cab see "S ection 4.1.1".
The starter pushbutton is at the engine front end.
The transmission gear shift lever must be in neu tral. Power to the starter switch is cut off
if gears are engaged. To shut off the engine, shift i njection pump control lever to stop
position.

36
2.3 Hand brake operation

To release:
r---- :~,-~'- ,s
To ensure perfect release of the hand bra ke, th e supply pressure i n th e hand brake cir- r .- .- --~_.-

cu it must be at least 5.5 bar (78 pSi). The brake pressure warn ing light i n the instru ment
, 3/ "'" &--~

cluster must not come on.

/ ;--
Dise ngage the lever of the hand brake valve from its lock and push it forward as far as it
wi ll go. The hand brake warni ng light (release control) must go out.

To engage:
Pull the lever backwards from the release position to the "on" position (catch). The hand
brake warning lig ht co mes on. For parti al braki ng, h old the lever in the desire d position
since it will otherwise automatically return to the release position. '.,. 'Jl

In the test position the trailer or semitrail er brake is released. ~

1 Release position
2 " On" position -lever not engaged in lock
3 "On" position -lever engaged In lock
4 Disengaging the hand brake lever from lis
lock
5 Test position

37
 2.4 Starting the vehicle and shifting gears

Do not drive off as long as a pressure of less than 7.0 bar (99 psi) is registered on the
duplex pressure gauge and the brake pressure warning light in the instrument ctuster is
on.

Do not set off i mmediately after the first few engine revolutions!
1'1 '1 '1 , 11, 1. Do not turn on heater until a coolant temperature of 1220 F (50 0 C) is reached. Shut
, '. the radiator shutter (optional).
2. Let the engine idle at moderate speed for a sho rt period of time.
3. Warm up the engine smoothly at medium engine speeds in the lower gear ranges .
4. Demand full engine performance only after the operating temperature has been
reached.
1 Actuat ion of radiator shuller
On level roads and on minor gradients the unloaded vehicle can be started in second
gear. First gear is required only when a loaded vehicle is started, when setting off on a
gradient or off the road.
Caution: Immediately after setting off, test brakes (service and parking brakes) on a dry
road affording good grip.

® ®® The brake is in good working order if the brake action of the wheels is uniform and if suf-
ficient deceleration is obtained. Your sound judgment will tell you whether the vehicle is
prepared for the road.
There must be no oil or water on the brake linings. If water has penetrated to the brake
shoes, apply service brake with light peda l force until the required brake action is
restored .
If even only one brake fai ls to work, stop immediately.

Shifting pattern transm ission G 3/50. G 3/60

38
Gearshifting

Observe tachometer during the ride. Keep wi thin economic range .

Always disengage clutch fu l ly. Do not move lever too quickly or exert force.
Engage re .... erse gear only at eng ine idle speed and with veh icle at a standstill.

Shifti ng pattern "double H gears hill" Transm ission

G 3190-8 GP

Transmission G 3/90 - 8 GP (714.3) and G 3/65-9 GP (714.2) with double H gearshift

pattern

Th e tran smission includes a baulked synchromesh 4-speed transm ission and one rear-
moun ted planetary type range change gearbox.
The transmission is in neutral whe n the gearshift lever is positioned in the gate between
3rd and 4th gears or 5th and 6th gears.
Speed ra ng e changes :
- Declutch , m ove gearshift lever to neutral, engage clutch.
The gearshift lever po int of resistance between th e speed ranges can be overcome by
lightly tapping the lever with your hand. Caution: Whi le doing this, do not hold the
gearshift lever.
The indicato r light fo r engaged speed range must com e on.
" L " = speed range R, C, 1st to 4th gear
" H" = speed range 5th to 8th gear
Declutch, move gearshift lever gently to the desired gear position and engage cl utch.
Gear ranges are changed pneumatically.
Shilting pattern " double H gearshift " Tran smission
A pressure of 6.0 bar (85 psi) is req ui red in the compressed-air system. G 3/ 65 - 9 GP

39
 Transfer case VG 500-3 W (750.5)

The transfer case should only be engaged when the vehicle is at standstill.

Shifting positions:
1. Road operation position.
2. Neutral position: No power is transmitted from the transfer case to the live axles.
3. Cross-country operation position: When the shift lever is moved to the cross-country
gear a lower speed ratio is engaged.

Engaging and disengaging differential locks

Shift va tve of transfer case VG 500 - 3 W
1 Road operation positi on
2 Neutral position
3 Cross-country oper ation position
Sh ift valve of differential lock
1 Disengaged
2 Engaged
Differential lock of transfer case (I nter-axle differential lock of live axles)
Live axle differential locks (inter-wheel differential locks)
Shifting combinations:
1. Inter-axle differential lock of live axles (transfer case)
2. Inter-wheel differential lock of live front axle
3. Inter-wheel differential lock of rear axle
Engagement:
The differential locks are engaged/disengaged by means of one control valve each lo-
cated on the engine cover (turn clockwise to engage - the "d ifferential lock " indicator
lights must come on - and counterclockwise to disengage).
It may only be engaged when the vehicle is stand ing or travelling at a low speed (walking
speed). Do not engage locks while the drive whee ls are spinning.
When starting off, accelerate slowly. Never proceed on paved roads with the differential
locks engaged as there is no differential action between left and right wheels on cor-
nering.
Change direction slightly several times if one of the "differential locks" indicator lights
fails to go out after the locks have been disengaged.

40
Engaging and disengaging the power take-off
The live power take-off is engaged/disengaged by means of a contro l valve on the en-
gine cover (turn clockwise to engage- the indicator light must come on -and counter-
clockwise to disengage).
Power take-off. NA 3/60 - 11 see picture.
With vehicle stationary and engine operating declutch (approx. 3-6 seconds) , engage!
disengage p ower take-off and reengage clu tch.

2.5 Breaking-in
NA 3/60 - 11 (NA .. power take-off)
1 Disengaged
With regard to service life, operational reliability and economical operation of the veh ic- 2 Lower output flange engaged
le, it is most important that the engine should not be run to the limit of its output during 3 Lower and upper output flanges engaged
4 Upper output flange engaged
the break-in period .

Break-in instructions

Up to 2000 km (1 200 miles)

Vehicles with manual transmission
Break in careful ly. Use only :y.. of the permissib le maximum speed in each gear. Refer to
marks on speedometer or tachograph.
Load : wi thout trailer, semitrailer units 50 % of the playload.
Vehicles with automatic transmission
Break-in carefully.
Avoid: high loads (full throttle driving), high engine speeds, kickdown if possib le.
Do not brake by selecting lower speeds.
Load: wi thout trailer, semitrailer units 50% of the ptayload.
From 2000 km (1200 mi les) on: Increase slowly to full speed.

41
 Wh ee l securing nu ts

It is imperative that wheel securi ng nuts on all new vehicles be retightened after 50 km
(30 miles).
On disk wheels, tighten wheel securing nuts crosswise.
On Tri lex wheels, tighten wheel securing nuts one after the other by going round the
wheel several times.
In addit ion, on planetary hl.1b reduction axles with trilex wheels t he wheel nuts securing
the wheel adapter to the wheel hub should be tightened crosswise.
Observe prescribed tightening torque.

450Nm
Disk wheel securing nuts
Centering via spherical spring washers
and wheol studs

2.6 Driving and braking

60kp Oi l and fuel consumption depends on vehic le equipment , individua l driving style and
operat ing conditions.

Ill, Examples
Vehicle equipment:
- tires (size, inflation pressure, condition),
body, air deflector,
drive unit rat ios,
addit ional eq uipment (air conditioner, supplementary heater, pto , visco fan) .
Style of driving:
- drive steadily at reasonable speeds, being aware of the road in front of you (avoid
600 Nm
frequent acceleration and deceleration),
Disk and Trilex wheel securing nuts
Centering by means ot whee l hub engine speed (keep within economic range).

42
Operating conditions:
- trailer and dump body operation ,
- hilly te rrain ,
city and short distance traffic,
- vehicle loads ,
- engine operation with vehicle stationary,
frequent cold starts.
For these reasons no prec ise statements can be made on the fuel consumption of the
individual vehicles.
Max. oil. consumption is approx. 1% of the fuel consumption.
Regular vehicle maintenance is one of the prerequisites for favorab le consumption.
The drive wheels must al ways be in fi rm contact with the ground (espec ially in
crosscountry operations). If the wheels on one side of the live axles are spinning, 300Nm
serious damage to the differential will result because the load on the differential gears Trilex wheel securing nuts
Trilex rim to wheel adapter ring
wi ll then be excessive. Engage the differential locks. if provided. When driving, observe Wheel nut M 18 -= 3(10 Nm (217 Ib-tt)
the gauges and control lights on the instrument pane) from time to time. M 20 = 350 Nm (253.2 Ib-ft)

Temperature gauge
Depending upon the operating conditions and ambi ent temperature, coolant operating
temperature in continuous operation ranges from 1580 to 203 0 F (70 to 950 C).
Brief vehicle operation (10 minutes at the most) at a coolant temperature of 2120 F
(100 0 C) is permiSSible. This temperature, however, should not be exceeded.
The cool ing system is provided with an emergency switch which actuates a buzzer in
the cab as soon as the coolant temperature rises to approx. 212 0 F (100 0 C).
Caution: Find out the cause of the high coolant temperature as soon as the buzzer
sounds.

Oil pressure gauge

No concern need be felt if the oil pressure drops to 2.5 bar(35.S psi) at operating tempe- 450Nm
rature and maximum rpm, orto 0.5 bar (7.1 psi) at idle speed. The operating rel iability of Trilex whee ls - Wheel adapter ring 10 hub
the engine is not jeopardized then. Centering via spherical spring washers

43
Uneconomic operation Tachograph
Continuously check and improve you r
driving habits by means of the tacho M

graph diagram. Use only original diagram

cards wi th correct scale. Check function
daily.
The more steadily the vehicle is driven the
lower is the fuel co nsumption. Short

I
bursts of speed will improve t he average
speed on ly negligibly.

J
Explanati on of samp le graphs :
Uneconomic operation - peaked graph
lines.
The vehicle was accelerated, braked
down abruptly and reaccelerated rapidly.
Economic operation - rounded graph li-
nes.
Economic operation
The vehicle was accelerated to economic
speed. The speed of the rol ling vehicle
-90 ",,' -. was gradually reduced to zero.
_----idbl_
.-----

~
- \;
lij.- ---..;

~tifL -- ~
~3t==-
- ---
. • ' \ ' , I'
l - ---
I" I i'l""'"
{fI
-=--
I
~

44
Tachometer
The most econom ical engine speed lies in the range in which the engine develops its
maximum torque. Refer to "Technical Data" .
The governor on the inject ion pump limits the maxi mum engine speed. When travelling
downhill, the vehicle determines the engine speed and the governor cannot limit it. The
driver himself must then ensure that maximum engine revolutions are not exceeded in
the individual gears or damage to engine, injection pump or prope ller shaft would oth-
erwise result.

Maintenance indicator in tachometer

Under severe operating cond it ions, do not carry out care and maintenance work in
compliance with mileage but according to mai n tenance indicator readings, fuel
throughput or operating hours.

Warning light - hydraulic brake contro l system

Caution: If the warning light comes on during the operation of th e brake peda l, stop at
once and determine cause. The warning light comes on if the hydrauli c brake control
system is defective. Have hydraulic brake control system checked immediately.

Warn ing li ght i n the instrument cluster

Caution: If the brake pressure warning light comes on, stop immediately and diagnose
cause. The brake pressure warning light comes on if:
1. a supply pressure of less than 5.5 ba r (78.2 psi) is reg istered on the duplex brake
pressure gauge
2. the supply pressure in the spring-operated brake circuit drops below 5.5 bar (78.2
psi).

Oil level warning light - engine

Brief blinking of the oil level warning light while the engine is running indicates that the
oil level is approaching the permiss ible minimum.
If it is on continuously when the engine is running, check oil level immediately with
dipst ick and replenish with oil.

45
 Indicator light - brake flu id and brake pad wear
The indicator light comes on if the fluid level in the reservoirs of the hydraulic brake
system is too low. Have brake system checked immediately.
The fluid leve[ can be too low:
1. if the hydraulic system is leaking
2. if the brake linings are worn

Charge indicator light

If the charge indicator light comes on whi le the engine is running, stop vehicle, switch
off engine and inspect V~belt.
Caution: Do not run engine without a V-belt.

1 Push button, exhaust brake

Brak[ng

When travelling down long inclines, exploit the engine braking effect by shifting down
to lower gear or by actuating the exhaust brake. The exhaust brake is also preferably
used in smoothly flowing traff ic.
The exhaust brake is the only brake not subject to wear.
Engage by depressing the button in front of the driver's seat.

Parking

Apply parking brake when stopping or park ing a vehicle on level ground or on declines.
Safeguard a loaded vehicle or a veh icle parked for an extended period with at least one
chock to prevent it from rolling away.
The taw demands a chock to be carried in the vehicle, easily accessible at a[1 times.
When parking a vehicle at night on public roads i n built-up areas, switch on standing
lights.
Reflector panels can also be used for this purpose if permitted by law.

46
2.7 Trailer and semitrailer

Extreme care and caution must be exercised when coupling the trai ler or semit ra iter.
Adjust wi nd deflector o n the cab according to th e body installed or th e semitrailer co u-
Trailer braked and secured by chocks.
pled. See instru ction plate on driver's door. Drawbar adjusted to coupling height.

Truck/ trailer combination :

Pri or to couplin g the trailer to th e t ruck, ti ghten trailer hand brake and release service
brake. Secure vehicle so it cann ot roll away by placing chocks at th e rear whe els. The
un braked trailer front ax le must remain capable of being pivoted. Adjust trailer drawbar
to coupling height. Caution : Be sure no one is standing between
tractor and trailer during the coupling operation.
Use caution when handli ng the drawba r, it may whip.
No one must stand between tractor and trailer when the tracto r is backing up!
Following the coup ling operation, check the pertinent locking device or in dicator (fee-
ler pin or safety button) for proper seating of the trailer coupling bolt.
Caution. Check the t rail er coupling daily for longitudinal play by forcefu lly m oving the
coup ling uni t back and forth . Do not grip the coupling jaw. Longitudinal play must not
be tolerated and should be eliminated immediately. It could result in the breakaway of
the tra iler.
Check fasten in g bolts of trailer coupling on rear cross member regularly for tight sea-
ting and tighten, if necessary.
Accord ing to manufactu rer's in st ru ctions, regu larly clean and grease trailer coupling,
check coupling rod m ount and coupli ng rod nu t.

Articulated truck :
If the semitrailer can be coupled by one sing le operator, care mu st be exercised to in -
su re that the upper fifth whee l on the semitaile r is a t least 50 mm (2 i n) above the lower
fifth wheel on the tractor.
Fo llowing the mounting of the semitrailer, the levers are to be sec ured in such a way as Trailer coupling (example)
to exclude the possi bility of unauthorized disengagement. Detach splash deflectors . 1 Feeler for coupling pin

47
 If the semi-trailer tractor is driven without semHrailer, the wheels must be covered by
mudguards or splash deflectors,
Note: If different kinds of semitra il ers are mounted, the f ree play between the kingpin
and the fifth wheel may be excessive. This is not permissible. Manufacturer's instruc-
tions must be observed.
Caution: The towing pintle of the truck tractor must only be used to receive the linkage
pilot rod of a forcibly steered semitraiJer (semitrailer must not be pulled with pilot rod),
to maneuver vehicles and to tow disabled vehicles .

Coupling of air lines and electrical cables

1 Splash deflecto r (example)
Air lines and cables must be routed to avoid subjection to excessive stress, chafing or
buckling when the vehicle negotiates bends. When connecting the cables the vo ltage of
the various electrical units on the t railer or semitrailer must be taken into consideration .
Caution: The 3rd brake of the trailer or semitrai ler is electrically controlled from the
tractor vehicle. When coupling a trailer or semitrailer, be sure it is equ ipped accordin-
gly.
After connecting the compressed-air lines to the trailer, adjust the brake pressure regu-
lator, if installed .

Coupling of air lines:

1. Connect brake line coupling half (yellow).
2. Connect supply line coupling half (red).
The shutoff valves in the coupling halves are automatically opened duri ng the coupling
action.

Uncoupl ing of air lines:

1. Detach supply li ne coupling half (red). The trailer is braked automatically.
Coupling the trailer
1 Plug so cket 24 V 2. Detach brake line coupling half (yellow) .
2 Plug socket 12 V Caution: Strictly adhere to this sequence when detaching the co upling halves as the
3 Coupling half, two line brake (brake pressure)
4 Coup li ng half, two-line brake (supply pressure) trai ler brake is otherwise released and the unbraked trailer may start rolling downhill.
5 Coupli ng half, single-l ine brake

48
2.8 Dump truck operation

1. L oa dIng

The dump body should be loaded in such a way that the center of gravity is in the center
of the platform. Bulky pieces of rock, debris, etc. mus t not be dropped onto the pl atform
but shou ld be loaded with care. If insta ll ed, make use of the tightening chai n in order to
prevent the side gates from gi~ing way.

2. Dump ing operation

During t he dumping op eration t he ve hicle must be positioned on fi rm level ground!

Pay particular attention to the horizontal position of the truck in rough terrain. The
wheels under load ·during the dumping operati on must rest on firm ground. The vehicle
might otherw ise turn over.
During the dumping operation the vehicle must be posi·
Do not ins ert securing pins c ros sw is e. Insert securi ng pi ns i nto the dump ing membe rs t ioned on firm level ground (danger of turning over)
on the side toward w hich dumping will occur.
The hydraulic pump will be activated by engaging the power take off. Declutch and ro-
tate control valve on engine cover (turn clockwise to engage-the indicator light "PTO "
must come on - and counter-clockwise to disengage).
Fo r dumping, turn the dump valve handwheel firm ly to the right.
The indicator light " dump body assembly " must light up.
Avoid lowering the raised dump body with the load still in place. If this is absolutely n e-
cessary, ope n the dump valve only slightly. When the dump body is com pletely down,
sh ut down hydrau li c p ump (disengag ing powe r take-off). The indicato r lig hts "du m p
body assemb ly" an d " PTO" must go out.
Slightly li ft the dump body and support it befo re removing the spare wheel under it
(danger). Disengage PTO and close dump valve.

3. Driv ing

Caution: Do not drive off before the dum p body is completely lowered. The indicator Dump v(l.lve
light "dump body assembly " on the instrument panel must not come on. 0 0 not drive 1 Raising
2 Lowering
vehicle with power take-off engaged. 3 Hydraulic syslem reservoir

49
 2.9 Air suspension

To position or dismount exchange dropside bodies , containers or semitrailers, raise or

lower frame by actuating the control valve (on side of chassis frame).

i .,- Raising or fowering the chassis frame:

- pull lever of contro l valve out = detent released
- swing lever of control valve backward = raising
- swing lever of contro l valve forward = lowering
Swjng lever to "Stop" position as soon as the desired height is reached.
Caution: After the changing process, engage lever of control valve in " Drive " position.

Note:
Shoul d the chassis be lifted too slowly (tractor/semitra iter combinations excepted) in-
1 Driv ing 3 Raising creased pressu re can be supplied via the booster valve wh i le the engine is running. De-
2 "0 " (stop) 4 Lowering
press push button on boost valve and hold in this pos ition un til the chassis has reached
the desired hei ght. A safety valve protects the air suspension system fro m overload.

Boo s\ valve
1 Push button

50
2. 10 Wint er operation

CO(rosion inhibiti on
The increasing application of thawi ng salts for clearing snow-covered or icy roads may
well be of benefit to roadworthiness, bu t sa lts cause damage to the undersections of the
vehicle and to the uni ts exposed to splash water. Thawing salts are co rrosive. Wash the
vehicle more often during the cold season to remove adhering thawing salts and depo-
sits of salty splash water from underbody, trailer coupling , painted and chromium-
plated parts and aluminium drop sides.
The vehicle shou ld be regularly inspected fo r corrosion. Brake, air, and oil l ines should
be checked wi th particular care.
As preventive measure, spray vehicle underside with wax-based preservative. If the ve-
hicle is used regu larly, repeat treatment with preservative now and then.
Spraying agents fo rmerly used, such as kerosene, diesel oil, diluted used oil, etc. must
not be used any more, sin ce they might soften or dissolve the co rros ion inh ibitor pre- Ant ifreeze unit
viouslyapplied. 1 Filler hole and dipstick
2 Setting handle (summer position)
3 Setting handle (winter pOSltion)
Air operated sect ion
During the cold season, condensation must be drained off daily and the air operated
section of the brake system must be prevented from freezing by adding common alco-
hol (ethyl alcohol).
The danger of ice fo rmation in the pip ing and brake va lves is greatest at outside tempe-
ratures ranging from 35° F to 26° F (+ 2° C to _ 3° C).
Vehicles wi th antifreeze unit
Before the onset of the cold seaso n, have the antifreeze unit cleaned at a MERCEDES·
B ENZ service station and the wick renewed, if req u ired .
The fluid level can be checked and common alcohol can be poured in on ly with the
handle in summer position: Push i n sett ing handle to summe r position and turn 90°
(locked). To inspect the fl uid level, unscrew dipstick. The fluid level must reach to the
upper dipstick marking.
At ambient temperatures below 41 ° F (5° C) , set antifreeze unit to winter position. Turn
sett ing handle 90° until it is pushed up by a spring.
Caution: A sufficien t level of common alcohol (ethyl alcoho l) must always be main tain-
ed in the storage tank, even in sum mer.

51
 Vehicles not equipped with antifreeze uni t
- Completely release compressed air.
Remove pipe behind governor.
- Inject '/2pint (1/4Iiter) of methylated spirit into the pipe leading to the compressed-ai r
reservoirs.
Reconnect pipe.
Start engi ne and run it until the governor cuts out - supply pressu re 8.1 bar (115 psi).
Depress brake pedal six to eight times.
- Actuate hand brake valve two to three times.
- Drain compressed-air reservoirs daily.
In continuous sub-zero temperatures, add methylated spirit in this manner every 2 to 3
days.

1 Air pump - "S1art·Pilot"

Lubrication
Chassis and brake system suffer particularly from the influence of snow and slush. Ti-
mely and thorough cleaning and greasing, especially of the brake linkage joints and yo-
I
...---- kes , of the brake units, the brake camshafts and the trailer coupling, will contribute to
avoid premature wear and to increase roadworthiness.

Coolants

Winter opera tion wi thout antifreeze protection is very dangerous and therefore not
permissible. Check cooling water blended with an ticorrosion/antifreeze agent for its
resistance to freezing several times during the cold season. Refer to section 3 .3.

Front panel opened (example)
1 Starting fuel reservoir, "Start-Pilot"
Engine oils
Change the engine oil at the onset of the cold season. As replacement, use an engine oil
of the specified SAE grades (viscosity range). Refer to "Fuels, coolants, lubricants,
etc ....

52
Diesel fuel
Winter grade diesel fuel of a sufficient fluidity is to be used during prolonged co ld pe-
riods.
As an exception, kerosene may be added to the diesel fuel if no win ter diesel fuel is
available or if the amb ient temperature drops below + 5" F (-15" C). Refer to " Fuels, f'
(i)~1
coolan ts, lubricants, etc. ".

Starting at ambient te mp eratures below + 5" F (- 15° C)

t!~TI
Supplementary heater ~':'~i
'~''l.
\~ i
2
~
~
Preheat the engine with the supplementary heater prior to starting it.
~
Filling the reservoir with starter ruel
1 Starter fuel flask

"' -
2 Reservoir
3 Maximum fuel level mark
" Start- Pilot"

(\\--:-t1 ;~~
The vehicle may be equipped with a "Start-Pilot " to fac ilitate starting even at extremely
low ambient temperatures .
0
Preparing the " Start-Pilot " for operation: fill reservoir with starter fuel. To do so , open
i ·
J
the reservoir cover, then remo ve the protective cap of the filler flask, press the flask \_~
valve onto the reservoir fi ller valve. Pour in starter fue l until the upper fuel level mark is
; 2
reached . Close the reservoir and seal the starter fuel flask with the protective cap.
~ 1·- ~
3/ . .J;l:
-' ;'<c_~
Start the engine as usual.
Push the starter button or turn key in steering lock to starting posit ion and simultane-

~~'1~
ously actuate the start pilot until the eng i ne fires: 1-2 air pu mp strokes per second.
Starter fuel comes in filler flasks only. They are available under Part No. 000 555 00 10
from any MERCEDES-BENZ service station. On ly original filler flas ks should be used.
The starter fuel is highly inflammable and should not be exposed to temperatures above
~, ;.
+22" F (+ 50" C) fo r extended periods of time. During the warm season, the filter flask
should therefore be removed from the vehicle, stored in a coo l room and protected from 1 Air pump " Start-Pilot"
2 Injection nozzle
fire. 3 Starter f uel reservOir

53
 General driving in structions
Do not set off immediately after the first few engine revolutions!
Idle the engi ne for a short period at medium speed. Then let the engine gradually warm
up in the lower speeds, avoid ing high engine load, until the normal operating tempera-
tu re of 158 0 to 203 0 F (70 0 to 950 C) has been attai ned. Engine may be run at full speed
only after this temperature has been reached.
In winter, use on ly tires whose treads afford good grip. If the drive wheels start spinning ,
try to get on firm ground immediately.
On slush and ice covered roads, pu t chains on the rear wheels. Referto manufacturer's
mounting instructions.

54
3 Fuels, coolants, lubricants, etc.

3.1 Diesel fuels

Diesel fuels should meet the min imum re- (depending on the degree of contamina-
quirements of DIN 51601 or such interna- tion). This will help to get rid of the offen -
tional specifications as the Ame rican sive odor.
ASTM D 975 No. 1- 0 and No. 2-D as well as
VV· F-800 a OF-A, OF-1, OF-2 and the Bri- Diesel fuels at extremely low
tish B.S. 2869 A 1, or even A 2 in cases of temperatures
emergency.
At very low temperatures the fluid ity of
All branded diesel fue ls common ly so ld in diesel fuel may become ins ufficient due
Central Europe meet these requirements. to paraffin separation. To avoid malfunc-
Change engine oi l in compliance with tions, diesel fuels of a lowered cloud point
"Maintenance category I" if diesel fuels are marketed during the cold season,
are used whose sulphur content exceeds
If winter diesel fuel is used, there will
O.5 ~,':' by weight. Marine diesel fuel, heat-
hardly be any malfunctions at ambient
ing oi l or the l ike must not be used. temperatures reaching as low as + 5° F
When fuel is filled from barrels , it should (_15" C).
be passed through a filter, a piece of Dependent on the temperature, add a cer-
chamois leather or even a clean flannel tain quantity of kerosene 1 if only summer
cloth , inserted into the tiller neck. The
suction port of the pump must be protect-
ed by a fine-meshed strai ner. Always al- Summer Supplementary
Iowa gap between the end of the suction Ambient temperature diesel fuel fuel
tube and the bottom of the barrel to pre- , F (' C) % %
vent deposits (dirt, sludge, water) , from
being sucked up. + 32 to + 14 ( 0 to - 10) 70
If diesel fuel has been spilt, the affected +1 4to + 5 (- 10 to - 15) 50
spots can be cleaned by using a mixture + 5 to - 4 (- 15 to - 20)
of 25 - 50 % vinegar and 75 - 50 % water - 4 to - 8 (- 20 to - 22)
diesel fuels or less cold resistant winter
diesel fuels are available or if temperatu-
res drop below + 5<> F (- 15° C) .
Shou ld gasoline have to be added in case
of eme rgency , never exceed a proportion
of 30%, Premium fuels must not be used.
Caution: The lower flash point of the
supplementary fuels increases the dan-
ger of explosions,
The engine output may drop according to
the proportion of supplementary fuel. For
th is reason, keep percen tage of fuel ad-
ded to the min(mum necessitated by the
ambient temperature.
1 The use of kerosene in road vehicles is not perm itted
in some countries. e. g. UK. Therefore. consult t he au-
thorities before such mi xtures are used.
Winter Supp lementary
diesel fuel fuel
% %
30 100
50 100
70 30
50 50

55
 SAE grades 3.2 Engine oils
Ambient
temperature I Single-grade
oils
Multigrade
oils
~

H. ..
·c The suitabil ity of the various engine oils is
specially tested in our engines. For this
reason, only use engine oi ls which have
bee'n recommended by our company.
sity (SAE grades) according to ambient
temperature.
Uncompounded engine oils must not be
H. •• used!

••
." .,
.,.
~
~ ~
~ " ~
~ i 08 specifications for service products:
HO engine oil sheet 226.0
The MERCEOES-BENZ factory or your
service station fills a new or a recondition -
."

."
."
.
.. -. -
-,. ~ - --- -
~ S3 engine oil sheets 227 .0/227.1
Super S3 engine oil sheet 228.1
Only use recommended engine oils corre-
ed eng ine with an initial operation oil.
This is a high quality oil wh ich was spe-
cially developed for the operating condi-
-" - ----
-•
"~ .
~
sponding to specification sheets 227.01
227.11228.1 for engine 352 A.
tions during the first 500 to 1500 km (300
to 900 miles).
~ MERCEOES-BENZ service stations have If the oil level reaches the minimum mark
1 SAE 40 o il may be used at ambient temperatures
all the information on recommended on the dipstick before the inspection
continuously above + 68° F (+ 20° Cl. brands. (500-1500 km [300-900 mi les]). the en-
gine may be topped up with recommend-
Caution: ed engine oil if no inital operation oil is
available.
In order to ensure suffic ient lubrication of
the moving parts , select engine oil visco-

56
3.3 Coolant
In the plant the engines are filled w ith a
coolant which is blended with an antieor-
rasion/ antifreeze agent (antifreeze pro-
tection down to - 22c F/- 30° C) and with
treating agent. Renew coolant every other
year.
In exceptional cases , Le. if no anticorro-
sion/ant ifreeze agent is ava il able or if no
antifreeze protection is required (e.g . in
tropical zones), 1% by volume (1 0 cc/ liter)
of treating agent must be used.

Cooling water
Water used as coolan t must meet spec ific service stat ion w ill adv ise you accord-
requirements which are mostly met by ing ly.
potab le water. Any MERCEDES-BENZ

Anticorrosion/antifreeze agents, treating agents

In order to preve nt damage to the coolin g A minimum of 33% by vol ume of anticor-
system, only use an app roved brand of rosion/ ant ifreeze agent is required for
anticorrosion/antifreeze agen t and treat- sufficient corrosion protection (antifree-
ing agent. Any MERCEDES-BENZ service ze protection down to _ 200 C/_ 4° F).
station will advise yo u according ly. Never use any more than 55% by volu me
of anticorrosion/an tifreeze agent.
Mixing ratio
Antifreeze protec- Cooling Anticorros ionl Treating
tion down to water % antifreeze agent agent
°C of by volume % by volume % by volume

- 30 - 22 54 to 59 40 to 45
approx . 44 max.55
- 45 - 49
Examp le:
Cooling system capacity approx . 27 liters (57.1 /47.5 USllmp. pt)
Ant ifreeze protection down to -30' C/- 22' F
Cooling water 15 titers (31.7/26.4 USllmp. pt)
Anticorroslon/antifreeze agent 12 liters (25.4/21.1 US/Imp. pt)
Treating agent 0.3 liters (0. 6/0.5 USllmp. pt)
57

On-vehicle tools behind the driver's and
aSs istant driver's seat
58
4 Vehicle service and maintenance
As any olher technical equipment your
vehicle requires servicing and mainte-
nance. Scope and frequency of mainte-
nance work depend primarily on the often
widely varying operational conditions .
The variable MB maintenance system
meets this requirement. It offers three
maintenance categories with varying
maintenance intervals.
Preventive maintenance work and jobs
required for the retention of the operatio-
nal reliability are itemized in the enclosed
maintenance booklet.
Special skills are requ ired tor inspections
and maintenance work. They cannot be
taught within the scope of these instruc-
tions, It is recommended to have these
jobs performed by the trained personnel
which is at your disposal in the large
number of MER CEDES-BENZ service sta-
tions .
Expert service is guaranteed by expe-
rience and regular technical instructions
from the factory, by workshop equ ipme nt
and service tools.
The MERCEDES-BENZ service station
certifies t he jobs carrie out in the main-
tenance booklet.
A small sticker, attached to the door post
of the driver's door by the service stat ion ,
is a reminder of the com ing service work .
Should any service an maintenance jobs
have to be carried out on a do-it-yourself
basis for organizational reasons, drain
oil, fuel or coolant into a trough or
something similar and not into the drain
or on the ground (env ironmen tal pollu-
tion). Operate stationary engine no longer
than necessary. When working on the ve·
hicle, adhere to safety regulations.
For lubrication use only high pressure
grease guns not exceeding a maximum
pressure of approx. 400 bar (5680 psi).
Grease guns without safety devices may
damage bearings, ball joints, seals, etc.
Carefully clean lubrication nipples prior
to the lubrication service and drain plugs
before unscrewing them.
Lubricate special bod ies and equipment
in compliance with manufacturer's in-
structions.
MERCEDES-BENZ special tools required
in addition to commercially available tool
kits and torque wre nches to work on the
vehicle can be obtained from the spare
parts department of any MER CEDES·
BENZ service station .
All MERCEDES-BENZ service stations
store the MERCEDES-BENZ original
spare parts required fo r maintenance and
repair work. Besides this bases are pro-
vided all over the globe intended to ensure
the rapid supply of MERCEDES-BENZ CEDES-BENZ original spare parts are in-
original spare parts. stalled, as they are subjected to most se-
vere quality inspections. Each part has
More than 200000 different spare parts,
been specifically developed, manufactur-
even fo r rather old vehicle models, are
ed or selected for and adapted to MER-
furthermore stocked in the central plant
CEDES-BENZ vehicles.
warehouses.
For this reason, only MERCEDES-BENZ
We guarantee maximum operational effi-
original spare parts should be installed.
ciency and reliability as wel l as optimum
retention of the vehicle value when MER-

Ve hicl e tools and em erge ncy equipme nt On-vehicle tools underneath 01 bunk

Short cab Long cab

- behind driver's and assistant driver's _ under the bunk.
seat.
Medium cab
under the cover plate behind th e driv-
er's and assistant driver's seat.

59
 4.1 Tilling cab
4.1.1 Tilting the cab
Caution: Prior to tilt ing the cab
shut off the engine
- lower guard on bu mper
- for safety reasons, c lear regio ns in
front of the cab and the gear shift lever.
Always tilt cab to final position.
Tilt ing forward :
1. Move transmission gear shift lever to
neutral.
2. On the short cab, unlock locking me-
chan isms behind driver's seat and as-
sistant driver's seat.
On the long cab, unlock locking
mechanism beh in d the driver's seat.
3. Shut all doors and front service flaps.
4. Move hyd raul ic pump valve lever in til-
• ting direction.
5. Actuate hydraulic pump until the cab is
tilted to its final position .
Vehicles wit h long cab : Only use round
bar to act ivate cab til ting pump .
, Caution : If the hydraul ic cab tilting sys·
tem fai ls or if no such system is insta lled ,
detach shi ft rod from transmission and tilt
cab with external aid (e . g. a crane).
Cab lacking device - short ca o
1 Locked }
2 Unlocked Pump lever (vehicl e tool kit)
60
Tilting in driving position:
1. Move hydraulic pump valve lever in tilt·
ing direction.
2. Actuate the hydraulic pump until the
cab is t ilted back into driving position .
Notes:
On the short cab, ensure that the rub-
ber gaskets are correctly positioned
on the fenders joined w ith the chassis
frame. Align rubb er gaskets, if neces-
sary. On the long cab, continue actua·
ting the hydraulic pump until firm
resistance can be felt during pumping
action.
3. On the short cab, lock locking mech-
anisms behind driver's seat and
assistant driver's seat.
On the long cab , check the position of
the safety lever behin d the driver's
seat.
4. Press shifting lever forward until shift
rod engages.
Note:
For vehicle operation the valve lever on
the cab tilting pump must point in driving
direction!
If no resistance can be felt whife actuat ing
the cab tilting pump :
Check whether or not there is sufficient
oil in the cab tilting pump.
If firm resistance can be felt when actua-
ting the cab til ting pump:
4.1.2 Lubricating tilting cab bearings (long and medium cab with comfort
susp ension - optional)
Tilt cab forward . Lubr icate cab bearings
with multipurpose grease at regular inter-
vals.
I Pump lever (vehicle 1001 kil)
2 Tilting back into driving position
3 Tilting forward
4 Oil finer hole - oil level
Check whethe r or not the cab locks are
unlocked . Check whether the valve leve r
on the cab ti lting pump poi nts in the
desired tilting direction,
1 Pump lever (veh icle too l kit)
2 Tilling back in to driving position
3 Till ing fo rward
4 Oil filler hole - 011 level
Cab locking device -long cab
1 Locked
2 Unlocked
I Pump lever (vehicle 1001 k it)
2 Tilling back Inlo driving position
3 Tilling forward
4 Oil filler hole - oil level
61
 4.2 Engine

4.2.1 Oil and filter change

Oil change should be performed after a
long distance drive, while the oil is still hot
and thin.
Drain oil from engine and from oil filter
bowl. Loosen center bolt of oil filter bowl,
remove bowl with filter element, drain and
clean with gasoline.
At each oil change, renew the filter ele*
ment and the gasket between filter bowl
and fi lter top. Inspect all other seal rings
for correct seating and damage. Renew if
necessary. Service oil drain plugs.
Place filter bowl against filter bracket in
an accurately upright position, push it up,
and tighten the center bolt somewhat by
hand or with a socket wrench.
Proper seating of the seal is important.
Tighten oil filter bowl carefully to the spe-
cified torque.
Screw in and tighten oil drain plugs.
Observe tightening torque.
Fill engine with oil.
Crank the engine (for no longer than 20

o
seconds) until oil pressure is recorded on
oil pressure gauge. To do so , actuate
exhaust brake to prevent the engine from
starting!
Note: If there is no supply pressure in the
compressed-air system, tilt cab forward.
Move control lever of inj ection pump to
stop position. Push starter button on en-
gine.
Then idle engine briefly and adjust id le
speed and check engine and the oil filter
for leaks. Shut it down and check engine
6
oil level after about 5 minutes. Replenish
Engine 352 Engine 352 A
1 Filter bracket 5 Drain plug 1 Filter bracket 5 Drain plug oil to the upper dipstick mark.
2 Filter element 6 Filter bowl 2 Seal ring 6 Center bolt
3 Seal rings 7 Cenler bolt 3 Filter element 7 Seal ring
4 Seal ring 4 Fi lter bowl

62
4.2.2 Inspecting and servic i.ng pape r air cl ea ne r
Inspection
Engine 352
Run the warmed-up eng ine at full throttle
(accelerator fully depressed) and observe
maintenance indicator. If the red field is
visible , clean or replace filter element.
Engine 352 A
If the entire red field becomes visible in
the maintenance indicator, clean or re-
new filter element.
Cleaning
1. Loosen securing nut and remove filter
element.
2. Cover up the inner space of the filter
element. Blow compressed air of a
maxim um pressure of 5 bar (71 psi)
along the ou tside in direction of the
folds . Then blowout the inner space
carefully.
Shou ld this cleaning process prove in-
adequate, the filter element can also be
washed.
To do th is, adhere strictly to the following
safety measures.
Use fi lter manufacturers' detergents.
Any MERCEDES-BENZ service station
will offer you advice. If no such detergent
is available, a non-foaming household
detergent may be used.
Cautio n:
Filter manufacturers ' detergents have a
strong degreasing effect. Protect your
hands with rubber gloves or skin protec-
tion cream. Never apply Iyes or hot fluids.
3. Soak filter element for 10 minutes in a
cleanSing solution of approx. 40° C
(104° F). Then swi ll in solution for ab-
out 5 minutes and rinse in clean water
un til c lear water drops off. Shake the
filter firmly and allow to dry in a dust-
free room (max. temperature
60° C/140° F). Install element only if
thoroughly dry. 1 Maintenance indicator paper air cleaner
4. Clean gaskets of filter element and
sealing faces in filter housing .
5. Prior to installation, check cleaned fil-
ter element and gaskets for damage
(cracks, holes). Use inspection lamp.
Renew damaged element.
6. Mark number of ti mes cleaned on face
of filter element. Install filter element
an d tighten securing nut.
Renew filter element after 3 cleaning jobs
or after 2 years at the latest.
Caution:
Dust deposi ts in the air intake ducts indi-
cate a leak in the intake system which Air cleaner in right wheel house
1 Filler housing
must be eliminated at once. 2 Filler element
63
 4.2.3 Servicing the oil bath type air cleaner

Check the oil level of the air cleaner regu -
lar[y. [n the event of large amounts of dust
entering the ai r cleaner, such a check
should be performed once a week, in ex-
treme cases daily checks are required.
The oil level must always reac h the mark.
It must be at least 5 mm (0.2 in) above the
layer of sludge which may have formed at
the bottom of the reservo ir.
In the event of increased contami nation
service air cleaner and replace oil. Un-
cleaned drawn -i n air will result in prema-
ture wea r of pistons and cyli nders. Wash
filter elem en t and filter housing with die-
sel fuel, blow them out with compressed
air and let them dry completely. Ref ill fil -
ter housing with engine oil only up to
mark. When reassembl ing the air cleaner,
check seals for perfect condition, rep la-
ce, if necessary.
Dust deposits in the intake passages indi-
cate that there is a leak in the intake sys-
tem which has to be eli minated at once.

011 bath I:,pe air cleaner

1 Maximum oil le"el mark
2 Air cleane r element
3 Air cleaner housing
4.2.4 Se rvicing dust separating valve

Regularly empty dust separating valve at treme cases daily. To empty, compress
the intake line. In case at heavy dust ac- rubber bellows.
cumulations , do so once a week. In ex-

1 Dust separatinJ valve

64
4.2.5 Removal and installation of cylinde r head cover

If heavi ly soiled , clean cylinder head co- Use only original necked-down bolts.
ver before removal. Renew cylinder head First tighten the bolts above the intake
cover gasket and seal rings below the fas- ports and then the center row bolts. Ob-
tening bolts. serve tightening torque .

4.2.6 Tightening cylinder head bolts

Following the tightening sequence, loo-
sen one bolt at a time and then tighten it to
the specified amount .
Use spec ial tool for cylinder head bolts
below rocker arm shaft.
Under no cirumstances must all bolts first
be loosened and only then be tightened.
After the tightening process, the valve
clearance must be readjusted.
Tightening cylinder head boils
1 Torque wrench
2 Special tool

17 ' 21' ~3)1

11; l'
, I
(e · 15 '1511
@l 19
L--'=--------=--_ '~
___=_ F .Cl!' 'i~ "' I
/l O"
Tigh teni ng sequence for cyt inder head botts
1 troug h 25

65
 4.2.7 Adjusting valve clearance

Check valve clearance with a feeler gauge
between contact points of rocker arms
and intake and exhaust valve stems on the
col d engine (not sooner than 20 minu tes
after the engine has been shut otf).
Valve clearance is adjusted for one cylin-
der (intake and exhaust valves) at a time,
at ignition TOC , i. e. when intake and ex-
haust valves are closed.
Cross check : Both intake and exhaust
valves are sl ightly open at the same time
(overlap) on cylinders whose pistons are
fired simultaneously. Piston of cylinders 1
and 6, 2 and 5, 3 and 4. The valve clears-
ance is adjusted by turning the ball pins
after l oosening their counternuts . Use
special tool to loosen and tighten coun-
ternuts. Following adj ustment, retighten
counternuts and check valve clearance
once more. Refer to " Techn ical Data " for
valve clearance.

Valve clea rance ad justm ent

1 Lock nut 3 FeQler gauge
2 Ball pin 4 Special too l

4.2.8 Lubricating flywheel ring gear

Remove cover plate from clutch housing.

Spread long-term grease over the ring
gear circumference. Install cover plate.

Lubricating flyw heel leeth

1 Cover pl ate

66
4.3 Fuel system
The injection pump is connected to the
engine oif cyc le and requires no mainte-
nance.
It has been set at the factory for optimum
efficiency and most economical fuel con-
sumption.
4.3.1 Cleaning of fuel tank
Disengage and remove fuel gauge send-
ing unit by turning it left out of bayonet
socket. Clean strainer on feed pipe.
4.3.2 Check and clean fuel precleaner
Regularly check fuel precleaner for soil-
ing (visual insp ection ). Clean soiled filte r.
Slacken knurled nut of wire clamp.
Swing wire clamp aside .
Detach inspection g lass and filter ele-
ment and wash in cleaning gasoline or
diesel fuel.
Any inspection of the injection pump and
the adjustment of the start of delivery
must be performed in a MERCEDES·
BENZ service station only.
1 Primer pump 4 Wire clamp with knurled
If necessary, flush fuel tank. To do th is, 2 To release
3 To tighten 5
00'
Filter strainer
screw out plug on the bottom of the fuel 6 Inspecl ion glass
tank and drain fuel.
Chec k gasket. Renew damaged gasket.
Install filter element and inspection
glass. Observe proper seating of gasket
and knurled nut.
Operate primer pump until the injec-
tion pump overflow valve opens audi-
bly.
- Check fuel precleaner for leaks.
67
 4.3.3 Renew al of fu el filte r ele ments

Loosen filter housing securing bolts. De- the installation of the new filter elements.
tach filter housings and remove filter Replace all gaskets. Finally bleed fuel sys-
elements. Clean filter housi ngs prio r to tem.

4.3.4 Cleani ng the felt fil ter el ements

As a prec aution , clean spa re filter ele- During this process cleaning fluid must
ments should always be carried along. enter the inside only by passing through

, .
Fuellilter
Fue l filtered poorly or not at all will render
the injectio n pump plungers unservice-
able due to excessive wear after only a
the filter element.
To ensure perfect cleaning , immerse filter
element in fresh clean i ng flu id once more
Fixing scre .....
short operating period. unt il it is completely soaked. Place a co m-
Never run the engine without filter ele- pressed-air gun at the one end of the filter
ments! element , plug the other end and blow
th rough with compressed air. Wash off
To clean a prematurely soiled felt filter
the foam formed on outside of the filter
element, proceed as follows:
element.
Unscrew filter fix ing screw, detach filter
Go through this process two to three
housing and re move filter element.
times .
Plug the filter element at both ends and
Clean filter housing before the filter ele-
brush the outside with a soft brush (no
ment is installed and renew all gas kets.
wire brush) in clean diesel fuel or petro-
leum. Rin se in fresh cleaning fluid several Finally bleed the fuel system.
times .

1 Fuellilter
2 Fuel filter
3 Fixing screws

68
4.3.5 Bleeding the f uel system
A comp letely bled fuel system is impera-
tive for the perfect operation of the engi-
ne. Under ope rating conditions , conti-
nuous bleeding is insured through the
overflow lines.
After any repairs to the fuel system or in
the event of driving until the fuel tank is
4.3.6 Injection nozzles
Dirt accumu lations in the fue l system will
result in malfunctioning of injection noz-
zles and cause black exhaust smoke and
erratic eng ine operation.
A defective nozzle must be replaced or
cleaned . Special skills are required for
completely empty, the entire system must
be bled manually.
Open bleed screw on injection pump and
actuate primer pump (on delivery pump)
until the fu el coming forth is absolutely
free of air bubbles. Screw in bleed screw .
1 Bleed screw - injection pump
th is job and it should on ly be performed in
a MERCEOES-BENZ service station. New
injection lines must be thoroughly clean-
ed prior to installation. Blow them out
with cleaning so lution (diesel fuel).
69
 4.4 Cooling system

Caution: Keep air intake free. Do not at·
tach any posters, badges or other trim in
the region in front of the radiator. The
cooling water temperature is controlled by
one thermostat.
Control is provided by a temperature
gauge in the instrument cluster. When the
permissib le coolant maximum tempera·
tu re is exceeded , a warning switch will
actuate a buzzer located in the cab.
Close radiator shutter (optional) for
quicker attainment of operating tempera·
Drain plug on radiator ture.
1 Drain plug The gradual rise of the coolant tempera-
ture above the usual level indicates a
failure in the cooling system. The cause
may be lack of water, a clogged radiator,
slack V-be lts, a faulty thermostat or a
defective fan with fluid coupling.
Check cooling and heating system for
leaks at regular intervals and renew ho-
ses, if requ ired.
If a substantial amount of cooling water is
lost through the water pump leak hole,
have the water pump renewed or repaired
in a MERCEDES-BENZ service station.
Radiator and heater hoses should be re-
placed by new ones when they have been
in use for an extended period of time (ap-
prox. fou r years).
Use only hose material and hose clamps
tested and recommended by us.

4.4.1 Draining coolant and filling system with coolant

Drain plug behind air compressor
1 Drain plug
Draining:
1. Remove cap of coolan t expansion
tank.
2. Open heater control valve.
3. Unscrew drain plugs.
They are located:
- On the radiator bottom.
- On the RH side of the engine beh ind the
air compressor.
After having drained the coolant , check
whether the drain ports are restricted by
residual matter. Seal drain ports.

70
Filling with coolant:
If possible, replenish coolant only if the
coolant temperature in the system is less
than 122 0 F (50" C). Replace cap of coolant
expansion tank.
4.4.2 Clea.ning COOling and heating systems
Cleaning the radiator
Blowout the radiator core from the en·
gine side with compressed air or a jet of
4.4.3 Fan with fluid coupling
In case of failure, lock the fluid coupling
(Le. rigid con nection between fan and
pu lley).
Tu rn nut of locking device by 180". Rotate
4.4.4 V· belts
Testing V-belt tension
Use " Krikit" tester
1. Lower feele r arm i n tester.
2. Position tester in the middle between
two pulleys. The stop must contact the
side of the V-be lt.
Operate engine until operating tempera·
ture is reached (thermostat has opened ).
Shut off engine and replenish coolant.
wate r until the radiator fins are free of for·
eign partic les (dust, insects, etc.).
locking of fluid coupling
1 Locking mechanism (e xample)
fan by hand until the locking pin engages.
Have fan exchanged at a MERCEDES-
BENZ service stat ion as soon as possi·
ble.
3. Continuously press the push button at
right angles ro the V-bel t until the crack
spring can be feU or heard to disen -
gage. Di scontinue pressure as other-
wise measuri ng data are incorrect.
4. Carefully lift off tester without alteri ng " Krikit" tester
the feeler arm position. 1 Push button
71
 5. Read off the V-belt tension at the inter-
section of the "KG" scale and the feeler
arm.
Specified value for used V-belts
V-belt section width:
12.5 mm = 30-40 on " KG " scale
6. Correct V-belt tension, if required.
Retensioning V-belts
Generator:
1. Slacken clamping screw.
2. Turn tensioning nut until the specified
value is achieved.
3. Retighten damping screw
Tensloning generator V-belt 4. Check tightening screw rubber mount
1 Clamping screw
2 Tension nut for damage and correct seating.
Power steering pump:
1. Slacken clamping screw and securing
bolt.
2. Turn tensioning nut until the specified
value is achieved.
3. Retighten, clamping screw and secur-
ing bolt.
4. Check tightening screw rubber mount
for damage and correct seating.
T ens toning Of power s.teering pump d rive belt (example)
1 Clamping s.crew 3 Securing bolt
2 Tension nul
72
Air compressor:
1. Slacken lock nut and securing bolts.
2. Turn tensioning bolt until the specified
value is achieved.
3. Retighten lock nut and securing bolts.
Renewal of V-belts
Only use tested and recommended
V-belts
1. Check V-groove faces of pu ll ey, re-
move (ust and dirt.
2 Release tensioning nut or screw until
the V-belt can be slipped on.
3. Turn tensioning nut or screw until the
specified value is achieved.
Specified value for new V-belts.
V-belt section width
12.5 mm = 45-55 on "K G" scale
4. Check V-belt tension once more after
running engine for 10-15 minutes.
Specified values for used V-belts must
be attained.
If in exceptional circumstances no tester
is available, tighten new V-belt tempora-
rily.
The V-belt must not deflect by more than
approx. 10 mm (0.39 in) from a straight
4.4.5 Checking thermostatic switch and buzzer
Prior to the onset of the warm season ,
have thermostatic switch and buzzer fo r
line when subject to thumb pressure.
Correct V-belt tension to specified value
for used V-belts as soon as poss ible.
V-belts refer to section 6.2.
the acoustic warning system checked at a
MERCEDES-BENZ service station.
Tensioning air compressor drive belt
1 Securing bolts 3 Counter nut
2 Tensioning bolt
73
 4.5 Clutch
The clutch is adjusted automatically. Ba-
sic adjustment of the clutch control me-
chanism is for example necessary after
the pedals have been worked on or after
the renewal of the master cylinder.
4.5.1 lubricating clutch release bearing sleeve
Lubricate clutch release bearing sleeve
with long-term grease according to spe-
Clutch housing (example)
1 Grease cup cifications in the maintenance booklet.
4.5.2 Bleeding hydraulic clutch control system
Bleed the hydraulic clutch control system
with a bleeding device or as follows: Du-
ring the bleeding operati on , always keep
reservoir filled to three quarters of its
capacity.
- Remove dust cap from slave cylinder
bleeder screw. Attach bleeder hose and
place in a jar.
- Unscrew bleeder screw 1- 2 revol u-
t ions. Actuate clutch pedal approx. 30
t imes by hand and return to initial posi-
Clutch slave cyli nder
1 Bleed screw tion.
74
This adjustment requ i res special skills
and should only be performed in a MER-
CEDES-BENZ service station.
Fill grease cup on clutch housing once
and turn all the way in. Do not overlubri-
cate .
Note: The piston of the master cyl inder
must return to its i nitial posit ion au to-
maticaffy (wet cy linder runn ing surface
with brake fluid ).
Caution: The pedal is pushed down
abruptly by the overcenter spring.
- Tighten bleeder screw. Detach bleeder
hose and replace dust cap. Top up
reservoir to maximum marking.
- Actuate clutch pedal until it returns to
its initial position automatica lly.
4.6 Tr ansm ission
4.6.1 Oil level che ck and oil change
Prior to unscrewing the screw plug, care-
fully clean its vic inity. Change oil imme-
Transmission G 3/50 (714.0) and G 3/60 (714.0)
Oil level check: In the correctly filled
transmission the oil level reaches the low-
er edge of the filler hole in the transmis-
sion housing . Add oil through the filler
hole, if required. If the oil level is checked
with the transmiss ion at operating tempe-
rature, do not allow any emerging oH to
drain.
Transmission G 3165 (714.2) and G 3190 (714.3)
Oil level check : In the correctly filled
transmission the oil level reaches the low-
er edge of the filler hole in the transmis-
sion.
If required , pou r oil through the filler hole.
If the o il level is checked with the trans-
mission at operating temperature, do not
allow any emerging oil to drai n.
diately after an extended trip while it is still
hot and thin . Service oil drain plugs.
2
Draining oil : Unscrew oil drain plug and
oil filler plug.
Filling with oil: Pour oil through the filler
Transmis sion G 3/50 and G 3/60
hole in the transmission housing until the 1 Filler hole - o il level
level reaches the lower edge of the filler 2 Oil drain plug
hole.
Draining oil: Unscrew all oil drain plugs
and the fi ll er plug from the transmission.
Filling w ith oil: Pour oil through the filler
hole in the transmission until the level
reaches the lower edge of the f ill er hole.
Transmi ssio n G 3165 and G 3190
1 Oil drain plug s
2 Filler hole - 011 level
75

Transmission G 3/65 and G 3190 w ith power take-off
NA 3190
, Oil drain plug , power take-off
2 Oil drain plugs. transmission
3 Filler hole - oil lell'el
Transfer case - VG 500-3 W
t Filler hole - oil l(oll'el
2 Oil drain p lug
76
Transmission G 3/65 (714.2) and G 3/90 (714.3) with power take-off NA 3/90
Oil level check : Idle engine approx. 2
minutes. The oil level in the correctly filled
transmission reaches to the lower edge of
the filler hole in the transmission . Add oil
through the filler hole, if requ ired. If the oil
level is checked with the transmiss ion at
operating temperature, do not allow any
emerging oil to drain.
Transfer case VG 500-3 W (750.5)
Oi l level check: The transfer case is fil led
co rrectly if the oi l level reaches the lower
edge of the filler hole in the transfer case.
Transfer case - VG 500 -3 W
1 Oil drain plug
Draining oil: Unscrew all oil drain plugs
and the oil filler plug from the transmis-
sion.
Filling with oi l: Pour oil through the fill er
hole in the transmission until the level
reaches the lower edge of the filler hole.
Screw in oil fi ll er plug and check oil level
once more.
Replenish oi l through the fill er hole, if re-
quired. If the oil level is checked with the
transm ission at ope rating temperature,
do not all ow any emerging oil to drain.
Draining oil: Unscrew oil drain plugs and
oil filler plug.
Filling with oil: Pour oil through the filler
hole in the transfer case until the oil level
reaches the lower edge of the filler hole.
Transfer case VG 850-3 W (750 .4)
OilleveJ check : Unscrew filler and inspec-
tion plug with angu lar dipstick and place
angular dipstick on the filler hole lower
edge.
The transfer case is correctly fi ll ed when
the oil level reaches the marking of the
angular dipstick.
Add oil through the filler hole, if required .
4. 6.2 Clean ing t he breather
Clean exterior of breather on the trans-
mission housIng as otherwise pressure
Draining oil: Unscrew 011 drain plug and
oil filler plug.
Filling with oil: Pour oil through the filter
hol e until the level reaches the dipstick
mark.
Slowly pou r the oil in the filler hole.
Trar"lsfer case VG 850 - 3 W
1 r:iller and Inspection plug with angular dipsticK
develops in the transmission housing
which may cause loss of oi\.
Transfer case vG 850-3 W
I Oil drain plug
77
 4.7 Live front axle

4.7.1 Oil level check and oil change

Prior to unscrewing the screw 'plug , care-
fully clean its vicinity. Change oil imme-
diately after an extended trip whi le it is
still hot and thin.
Oi l level check: The front axle is filled co r-
rectly if the oil level reaches the lower
edge of the filler hole in the differential.
Add oi l th rough the filler hole, if req uired.
ShoUld the oil level be checked with the
front axle warmed up, do not aHow any
emerging oil t o drain.
Draini ng oil : Uns crew oil drain plug and
oil filler plug.
Filling with oil: Pour oi l through the filler
hole in the differential until the oil level
reaches the lower edge of the filler hole.

Liye fro nt axle (example)

, Filler hole - oil leyel
2 Oil drain plug

4.7.2 Ring gear adjusting screw

Ring gear adjustment must be checked Then loosen adjusting screw by one sixth
periodically. To do this , back off lock nut of a turn and secure in this position by
and screw in adjusting screw until resis- tigh tening the lock nut.
tance can be felt.

4.7.3 Clean i ng breather

Live IrOtll axle Clean exterior of breather on differential in the differential housing which may
1 Adjusling screw
2 Lock nul housing as otherwise pressure develops cause loss of oi l.

78
4.8 Rea r axle
Rear axle Hl 7 (740.1)
On the p lanetary hub reduction gear axle
the axle center housing and the axle
tubes are welded together to create the
supporting member.
Rear axle Hl 4 (744.3. 744.4, 744.5, 745.6)
On the hypoid axle the driving member
housing serves as a supporting member.
4. 8.1 Oil level che ck and oi l c hange
Rear axle HL 7 (740.1)
Prior to unscrewing the screw plug , care-
fully clean its vicinity. Change oil imme-
diately after an extended tri p while it is
still hot and thin .
Oil level check: Differential and planetary
hub reduction gears are filled correctly if
the oil levels reach the lower edge of the
respective filler holes.
If necessary, add oil through the fille r
hole. Should the oil level be checked with
the rea r ax le wa rmed up, do not allow any
eme rgi ng o il to drain.
Power is transmitted to the w heels from
the differential via axle shafts and one
planetary hub reduction gear in each
wheel hub.
The power is transmitted from the differ-
ent ial direct to the wheel hubs via axle
shafts.
Rear axle Hl 7
1 Filler plug - oil level
2 Oil drain plug
Draining oil: Unscrew oil drain plugs and
oil filler plugs from differential and plane-
tary hub reduction gears.
Filling with oi l: Pour oil through the filler
holes in the differential and in the plane-
tary hub reduction gears until the oil level
reaches the lower edge of the filler ho le.
Note:
Use special tool to fill the planetary hub
reduct ion gears with oil. Planetary hub reduction gear
1 Special tool for filling with oil
2 Oil drain plug
79
 Rear axle HL 4 (744 .3, 744.4, 744.5, 745.6)
Prior to unscrewing the screw plug, care -
fu lly clean its vicinity . Change oil imme-
diately after an extended trip while it is
still hot and thin.
Oil level check: The rear axle is filled cor-
rectly if the oil level reaches the lower
edge of the filler hole in the differential.
Add oil through the filler hole, if required.
Should the oil level be checked with the
rear axle warmed up, do not allow any
emerging oil to drain.
Draining oil: Unscrew oil drai n pl ug and
oil filler plug.
Filling with o il : Pour oil through the fi ller
hole in the differential until the oil level
reaches the lower edge of the filler hole.

4.8.2 Cleaning breather

Rear axle HL 4
1 Filler plug - oil lellel
Clean exterior of breather on differential in the differential housing which may
2 Oil drain plug housing as otherwise pressure develops cause loss of oil.

4.8.3 Ring gear adjusting screw HL 4 (744.3, 744.4 , 744.5, 745.6)

Ring gear adjustment must be checked Then loosen adjusti ng screw by one sixth
pe riodically. To do th is, back off lock nut of a turn and secure in this pos ition by
and screw in adjusting screw until resis- tightening the lock nut.
tance can be felt.

Rear axle HL 4
1 Adjusting screw
2 Lock nut

80
4.9 Steering
For safety reasons, perform maintenance
jobs at regular intervals.
Such work demands special skill s and
shou ld only be carried out at MERCE-
DES-BENZ service stations.
4.9.1 Checking the steering linkag e
Drag link ends and tie-rod ends must be
periodically checked for excessive play.
Lift front axle. The balls must rest in their
4.9.2 Oil level check and oil change
Manual steering:
Clean area around screw plug before un -
screwing the plug! When the steering
gear is correctly filled, the oil leve l is
30- 40 mm (1.2-1.6 in) from the upper
edge of the filler hole. The oil need not be
changed.
Power steering:
Oil level check: In the running engine the
oil level must reach the upper dipstick
marking, in the stationary engine approx.
1-2 cm/O.4-0.B in above th is marking.
Power steering:
In case of emergency, i. e. when the hy-
draulic system fai ls, the vehicle can con-
tinue to be steered w ith increased effort
because the mechanical power transmis-
sion is retained.
sockets witho ut play. Socket caps and
seals must be tight and undamaged. Manuaj steering
Check all bolts and nutsJor tight seating. 1 Filler and inspection plug
Oil change : Jack up front axle of vehicle.
remove drai n plug. Take off reservoir fil-
ler cap. Idle the engine for a short time-
10 seconds at the most- unti l the oi l has
bee n scavenged from pump and reser-
voir.
Turn st eering gear from lock to lock upon
shutting the engine off, until the oil stops
draining. Screw drain plug in agai n and
install new filter element, then fill reser-
voi r to the brim. Crank the engine wi th
starter - while engaging the exhaust Power steering
brake - and add oil continuously. Then 1 Drain plug
81
 run the engine at idle speed and progres-
sively turn the steering wheel from lock to
lock. This will bleed the steering system
automatically.
Allow engine to idle until no more air
bubbles emerge in the oil reservoir. Posi-
tion cap and tighten it. Ensure correct
seating of gasket. Theoillevel must reach
the upper dipstick mark when the engine
is operating.

4.9.3 Checking the toe-in

251190
Front end panel opened
Power steering oil reservoi r
1 Filler hole
2 Oil level d ipslick
For all measure ments on the front axle,
position ve hicle on a perfectly level sur-
face. The tires must be inflated to equal
pressure. Looseness in wheel bearings,
rie rod ends and drag link ends must not
be tolerated. The toe-in may be checked
on an empty or loaded vehic le. To meas-
ure toe-in (stee rin g in straight-ahead po-
sition), mark measuring points on the rim
flange in front of the axle at wheel cen ter
height, using chalk or colored penci l.
Measure the distan ce between these two
poi nts.
Move the vehicle backwards or forwards
1/2 wheel rotation and measure the dis-
tan ce between the two points whi ch are
now located behin d th e front axle.
The difference in measurement betwee n
the distance of the two points before and
atter the wheel rotation is the amount of
toe-in.
Aim for a toe-in of "0" as this means min-
imum tire wea r.
Vehicles wi th straight tie-rod :
After having loosened the clamping
sleeves, the tie rod can be adjusted infi-
nitely.
Veh icles with offset tie-rod :
Toe-in is adjusted by pushing one end of
the tie-rod out of the steering arm by
means of a pusher (special tool).
Observe spec ified torque to which the
nu ts have to be retightened.

82
4.10 W heel s and tires
4.1.0.1 Spare wheel location
On drop-side trucks the spare wheel is
located under the chassis frame end. To
lower it, crank the winch until the cable is
tight, then loosen the two fixing nuts on
the spare wheel carrier. Lower spare
wheel with the winch. Payout cable com-
pletely. Pull out spare wheel to the side or
to the rear and stand up. Unscrew spare
wheel carrier.
Upon special request the spare wheel can
be mounted on the side of tractor units.
To lower, rotate crank until the cable is
Spare wheel below chassis frame end
1 Spare wheel carrier
tight. Remove fixing bolts of spare wheel
carrie~. Use the winch to bring the spare
wheel down. Take the spare whee l off the
carrier (afte r having removed both claw-
type tensioners in the case of Trilex rims).
On dump trucks the spare wheel is locat-
ed underneath the platform. To remove it,
~aise and support the dump body.
The spare wheel attachment must be fre-
quently checked for safety reasons.
Spare wheel bale ,v chassis frame end
, Clamping nut
2 Cran k
Spare wheel at veh icle side Dump truck spare wheel (example)
1 Clamping nuts , Support
2 Winch
83
 4.10,2 Wheel change
Caution: When changing wheels, speci-
fied tire load capacities (PR) and pres-
sures are to be observed. Refer to " Tire
pressure chart " .
Should tractor vehicle and full trailer/se-
mitrailer be equipped with different type
disk wheels (centering by means of whee l
hub or spherical spring washers), carry
along a spare wheel designed for center-
ing via spherical spring washers. This
wheel can also be mounted and used in
place of a hub centered wheel until there
23 47" is an opportunity fo r repairs. For mount-
ing, use wheel stud nuts intended for
Location of jack - front axle
wheel hub centering (flat collar nuts) but
no spherical spring washers. Tightening
torq ues are the same as for "wheel hub
centering".
Secure vehicle to prevent it from rolling
off.
Position in g of the jack, front:
Under the pertinent spring , directly be-
hind the front ax le.
live front axle
At front axle, below the axle tube, defini-
tely not under the differential housing.
Positioning of the jack, rear:
At rear axle, below the axle tube, defini-
tely not under the differential hou sing.
26179 Do not damage the threads on the bolts
Location of jack _ live front axle (exa mple)
84
when removing or installing the disk
wheels.
Be cautions when dismounting the
wheels.
1. Unscrew the wheel nuts holding the
wheel nut covering.
2. Loosen all whee l nuts and unscrew
with the exception of three wheel nuts
in staggered position.
3. Remove the three last wheel nuts only
after ascertaining that the wheels on
the wheel studs are not subject to any
stress.
Before diskwheels are pOSitioned, re-
move rust and dirt from contact surfaces
of brake drums, rims and wheel nuts.
Apply some graphite paste to bolts in or-
der to avoid "jamming" of the wheel nuts.
Disk wheels centering vja spherical
spring washers and wheel studs:
Prior to positi oning the inner wheel (twin
wheels) make sure all spherical rings are
properly seated. After having positioned
the ou ter wheel, screw in and tighten two
to three wheel stud nuts together with
spherical sp ring washers. Make sure
wheel is correctly centered (wheel bolts
exactly in the center of the wheel disk
holes).
Position and tighten remaining spherical
spring washers and wheel stud nuts.
For the tightening of the wheel securing
nuts, refer to sect ion 2.5.
4.10,3 Tire inflation connection
The tire inflation connection is located at
the front side of the governor. To inflate a
tire, remove protective cap and connect
tire inflation hose. Reduce supply pres-
sure in the compressed-air brake system
4.10.4 Tire change
Remove rust and dirt from rims and rings.
Coat tire contacti ng area of rims and rings
with a specially developed mounting
paste or with paraffin, glycerin or similar.
Powder i nside of tires and the tubes with
ta lcu m.
Vibration in the steering ("front wheel
shimmy") may be caused by wheel unbal-
ance. Have the wheels balanced in a
MERCEDES-BENZ service station. Use
approved rims only. Super tires may only
be fitted to super rims or TriJex rims.
The wheel nuts of a changed wheel must
be checked after 50 km (30 miles ) and
retightened, if necessary. Thereafter pe-
riodic inspections will do.
to approx. 6 bar (85.3 psi) e. g. by actuat-
i ng the serv ice brake several times. Start
engine. Maximum air pressure available
for tire inflation is 10 bar (142 psi).
location of jack _ rear axle
Standard or reinforced tires can also be
fitted to super rims or Trilex rims . Stamp-
ed on the rims are rim size, spare part
number and manufacturer's name. Only
use parts bearing the same designation.
Every tim e tires or wheels were changed
on the front axle, make sure that wheels
turn freely when the steering is attulllock
position . If required, have wheel turning
angle adjusted at a MERCEDES -BENZ
service station.
Location of jack - rear axle
85
 4.11 Brake system
4.11.1 Checking the brake lines
Regularly check brake lines for leaks and
be sure they are in good condition. Re-
place brake lines if they are kinked or flat-
tened or if signs of chafin g are visible.
Brake lines showing even minor damage
must be replaced.
4.11.2 Lub rication 01 exhaust brake linkage
1 Th ickness of lining
2 Plug
Add a few drops of oil to the exposed
linkage ends and to the sl iding surfaces of
the levers every once in a whi le. Do not lu-
bricate the throttle valve bearing. It is
made of heat-resistant material. Lubri-
86
Commercial vehicles designed to haul
chem icals and ac ids are particularly jep-
ardized by brake line corrosion. Besides
vehicles intended fo r th e transportation
of cement, lime, animals and hides, this
categ ory includes brewery vehicles and
similar.
cants would form crusts and jeopardize
the function of the valve.
Necessary adjustments hould be carried
out in a MERCEDES-BENZ service sta-
tion .
4.11.3 Checking the brake linings
Check thickness of front and rear wheel
brake linings through the inspection ho-
les (inner side of wheels - brake anchor
plate) at regu lar intervals.
Minimum thickness : 5 mm (0.2 in).
4.11.4 CheckIng service brake adj ustment (veh icles with hydraulic brake system)
To check the service brake, proceed as
follows:
1. Dep ress control pin on brake booster.
2. Drive vehicle and apply full braking ac-
tion.
3. If the control pin has moved outwards,
readjust service brake.
4.11 .5 Adjusting the service brake (vehicles with hydraulic brake system)
Postpon ing a necessary adjustment of
the brakes will jeopardize the operatio nal
reliabi lity of the vehicle.
Check thickness of brake linings prior to
adjusting the brakes.
Brake dru ms must be co ld for adjustment.
Renew brake linings immediately if they
are worn down to minimum thickness
(see marking on brake lining).
This work requires special skills and
should therefore only be performed at a
MERCEDES-BENZ service station.
4. Press in co ntrol pin again.
5. Drive vehicle once more and app ly full 1 Brake booster
brak ing action. 2 Control pin
6. If the control pin has again moved
outwards , bleed brake system.
Jack up the vehicle until the wheels can
be turned . Loosen fixing screws of lock-
ing plates (if fitted). Turn the adjusting
bolts until the brakeshoesarejn firm con-
1 Fixing screw - locking plate
tact with the bra ke drums. 2 Adjusting boft _ slackening brake shoes
3 Adjusting bolt _ tightening brake shoes
4 Inspection hole - brake lining
87
 Back off the adjusting bolts (no more than
30 mm [ 1.2 in]) until thewheels can just be
turned freely. Tighten fixing screws (if fit-
ted). If no furthe r adjustment is possible,
the brake linings are worn down and must
be replaced.
To make sure the brakes are properly ad-
justed, drive the vehicle for a whi le with-
out applying the brake to find out whether
the brake drums are being heated by
dragging brake shoes.

4.11 .6 Adjusting the brakes (vehicles with compressed-air brake system)

Slack adj uster -Iront axle
1 Inspection hole - th ickness of lining
Slack adjuster - live axle
1 SlOp disk
2 80l t
3 Adjusting bolt
Vehicles without automatic slack adjusters
Postponing a necessary adjustment of
the brakes will jeopardize the operatio na l
reliabili ty of the vehicle .
Check thickness of brake linings prior to
adjusting the brakes.
Readjustment is necessary if the effect ive
stroke of the diaphragm rod is exceeded
(diaphragm rod travel more than35 mm =
1.4 in).
Brake drums m ust be cold for adjustment.
Jack up veh icle so that wheels turn freely.
The brakeshoes are adjusted by means of
the adj ustment screw on the slack adjus-
ter. Turn adjusti ng screw until the brake
shoes con tact the brake drum and the
wheel can no longer be rotated. Then tu rn
back the adjusting screw by 1/3 to 1/2revo-
lution until the brake drum just runs
freely .
To make sure the brakes are properly ad-
justed, drive the vehicle for a while with -
out applying the brake to find out whether
the brake drums are being heated by
dragg ing brake shoes.
The hand brake is automatically adjusted
when adjusting the service brake on the
rear wheels.
Caution : The diaphragm rods must not be
disturbed when the brakes are adjusted. If
th e suspicion arises that this has happen-
ed, or if the hand brake pulls uneven ly,
then the brake system assembly must be
adjusted. This must be carried out exclu-
sively in a MERCEDES-B ENZ service sta-
tion.

aa
Vehicles equipped with automatic slack adjusters
Hand brake and service brake are sel·
fadjusting. The clearance between brake
linings and brake drums is controlled by
4.11.7 Checking automatic slack adjusters
1. Secure vehicle to prevent it from roil·
fng away.
2. Replenish supply pressure in com·
pressed·air system (cutout pressure).
3. Measure wheel cylinder piston stroke
by comparing full braking position and
re leased brake position.
4.11.8 Adjustment of hand brake
Vehicles with hydraulic brake system
The brake must be adjusted if
1. Rear wheels are braked unequally.
2. During the braking action the piston
rods of the spring·operated brake cyl·
inders travel more than 60 mm (2.4 in).
an automatic slack adjuster. If the clea r·
ance exceeds the above·specified value,
it will be reestab lished infinitely.
Specified values for front axle:
15-30 mm (0.6-1.2 in)
Specified values for rea r axle: Position of indicato r disk on slack adjuster (example)
1 Brake lining new
20 - 35 mm (0.8-1.4 in) 2 Brake lining worn
If these values are not attained, carry out
function test.
This wo rk requires special skills and
should therefore only be performed at a
MERCEDES·BENZ service station.
Prior to the adjustment of the hand brake
the service brake must be adjusted. The
. hand brake is adjusted by means of the
tu rnbuckles on the pull rods. The
spring~operated brake cylinders must be
Vehicles w ith hydraulic brake system
pressurized (full supply press ure in the 1 Spring·loaded brake cylinder
compressed·air system). 2 Turnbuckle
89
 Readjust hand brake in the following se-
quence:
1. Slacken turnbuckle lock nuts.
2. Rotate turnbuckles until the rear
wheels brake evenly. Reverse turn-
buckles by '/ 2 to 1 revolution.
3. Tighten turnbuckle lock nuts. Be sure
not to twist the l inkage yokes.
Veh ic les with hydraulic brake system and
air suspension
1 Adjusting screw 3 Lock nuts
2 Stop screw 4 Brake shaft
Vehicles with hydraulic brake system and air suspension
The brake must be adjusted if
1. Rear wheels are braked unequally,
2. Durin g the braking action the piston
rods of the spring-operated brake cy-
linders travel more than 55 mm
(2.2 in.).
Prior to the adjustment of the hand brake
the service brake must be adjusted.
The hand brake is adjusted at the brake
shaft setting levers.
1. The spring-operated brake cylinders
must be pressurized (full operating
pressure).
2. Slacken the lock nuts of the adjust ing
screws and of the stop screws.
90
l1the adjustment reserve on the turnbuck-
les is i nsufficient, set back brake lever on
the brake shaft by one tooth.
The adjustment of the hand brake de-
mands special skills and should only be
carried out at a MERCEDES-BENZ ser-
vice station.
3. Unscrew stop screws.
4. Turn in adjusting screws until the
brake levers are just free of play. If ne-
cessary, reposition adjusting !ever on
the sp lines.
5. Back off adj usti ng screws by 1/4revolu-
tion and tighten lock nuts.
6. Turn in stop screws and tighten lock
nuts.
The adjustment of the hand brake de-
mands special skills and shou ld on ly be
carried out at"a MERCEDES-BENZ ser-
vice station.
4.11 .9 Releasing spring-loa ded brake cylinder with depressurized
compre ssed-air syste m
Vehicles with hydraulic brake system
In case of emerg ency or in the workshop
the spring-loaded bra ke cylinder can be
re leased man ually or pneumatically (op ~
tional extra).
Manual release
Sec ure vehicle to prevent it rolling away.
Remove protective sleeves from spring-
loaded brake cylinder piston rods.
Back off lock nuts and tig htening nuts of
manual release devi ce approx. 70 mm (2.8
in) until the wheels rotate freely. Restor-
ing functional co ndition of spring-loaded
brake cylinders: Bring brake system up to
full operating pressure. Move hand brake
lever to release position. Screw interme-
diate shaft levers finger-tight onto the pis-
ton rods with the ti ghtening nuts while
counterho lding the piston rods at their
ends with an open end wrench. Secure
tightening nu ts with lock nuts.
At regular interva ls, check whether the
threads of the spring-loade d cylinder pis-
ton rods are clear and undamaged.
Pneum atic re lea se
Pul l back hand lever of the hand brake
valve to full braking position (notch).
Press push bu tton valve above instrument
panel.
Releas e device on the spring-loaded brake cylinder
The spri ng-loaded brake cylinders w ill be 1 Protective sleeve
2 Lock nut
pressurized with compressed air from the 3 Tensioning nut
circuit of the secondary co nsumers.
In the correctly functioning hand brake
circui t the push button valve cancels itself
automatically.
Release position on the spring-loaded brake cylinder
1 Lock nut
2 Tensioning nut
3 Brake lever
4 Pin
5 Piston rod
6 Spring-loaded brake cylinder
91
 Vehicles with hydraulic brake system and air suspension
Vehicles with compressed-air brake system
In case of emergency or in the workshop
the spring-loaded brake cylinder can be
released manually or pneumatically (op-
tional extra).
Manual re lease
Secure vehic le to prevent it roll ing away.
Back off re lease bolt until wheels rotate
freely.
Caution: Prior to operating the vehicle,
restore operational condition of spring-
loaded diaphragm cylinders. At regular
Pneumatic release
Pu l l back hand lever of the hand brake
valve to full braking pos ition (notch).
Press push button valve above instrument
panel.
The spring-loaded brake cylinders will be
pressurized with compressed air from the
circuit of the secondary consumers .
In the correctly functioning hand brake
circuit the push button valve cancels itself
automatically.

Release device of spring-loaded brak e cylinder

intervals, check release bolts for ease of
(example) movement with the hand brake re leased
1 Braked position (cyli nders pressurized).
2 Released position

1 Push button val~e , emergency re lease mechanism

92
4.11 ,10 Hydraulic clutch and brake control sy ste ms - check fluid level

The translucent reservoir is accessible An indicator light on the instrument panel

upon opening the front flap , To open the
front flap , first open the front panel and
then push th e locking sp ring to the RH
sid e from inside.
The flu id leve l can be ve rified withou t re-
moving the reservoir cap. The reservoir
must always be sufficiently filled. Do not
fill above upper mark ing (maximum
marking).
lights up if the hydraul ic component of
the brake system is defect ive.
Th e necessi ty of frequent flui d rep l en~
ishments indicates a leak in the hydraul ic
clutch or brake co ntrol systems wh ich
must be chec ked immedi ately. Always
screw on cover of reservoir tigh tly.
Renew brake flu id every other year.

Fron t flap opened

1 ReservOir
2 lock ing spring - front flap
4.11 .11 Bleeding hydraulic brak~ control system
Bleed t he hydraulic brake co ntrol system
of the brake system assembly with a
bleeding device or as in the fol lowi ng se-
quence.
Bleeding is carried out via hydraulic
clutch control system. Al l bl eeder screws
must be firm ly tightened. Add brake fluid
during th e bleeding operation so as to in -
sure tha t the reservoirs are always filled to
three quarters of thei r capacity.
1. Remove dust caps from bleede r
screws of clu tch slave cylinder and
brake slave cylinder (on brake boos-
te r).
2. Attach bleeder hose of about 1 m Brake slave cylinder (hydraulic brake Sys1em) Clutch slave cylinder
(3.2 ft) length to bleeder sc rews of 1 Bleed screws 1 Bleed screw

93
 clutch and brake slave cylinders (1st
circuit).
Unscrew both bleeder screws 1-2 re-
volutions.
3. Actuate clu tch pedal slowly and retain
in position.
Caution: The pedal is abruptly pushed
down by the overcenter spri ng.
4. Tighten bleeder screw on cluch slave
cylinder.
5. U ft up clutch pedal by hand.
6. Again unscrew bleeder screw on
Brake slave cylinder (compressed -air brake system)
1 Bleed screws
4.11.12 Hydraulic brake system - checking fluid level
The translucent brake fluid reservoir of
the hydraul ic system of the brakes is on
the master brake cylinder. The fluid level
can be checked without unscrewing the
cap. The brake fluid reservo irmu stalways
be sufficient ly fil led to about 10-20 mm
(0.4 -0.8 in) below lower edge of cove r.
An indicator light on the instrument panel
lights up if the hydraulic component of
the brake system is defective. The neces-
sity of frequent flu id reple nish ments indi-
cates a leak in the hydraulic brake system
Hydraulic brake system
1 Brake fluid reservoir on mas1er brake cylinder
94
clutch slave cylinder 1- 2 revolutions ,
actuate clutch pedal and hold down.
Close bleeder screw and lift up clu tch
pedal. Repeat this process about 20
times.
7. Re peat bleedi ng procedure on 2nd
ci rc uit.
8. Tu rn in bleede r screws on clutch slave
cylinder and on brake slave cylinder.
Replace dust caps.
For reasons of safety, bleed brake system
scrupulously.
whic h must be checked. Always screw on
cove r of reservoir tigh tly.
Use only tested and recom mended brake
.fluid brands for replenishment or renew-
al. Observe boiling poi n t (DOT 4).
Replace brake fluid once a year, most suit-
ab ly in spring.
A small sticker, attached to the door post
of t he driver's door by the MERCEDES-
BENZ service station, is intended to serve
as a remi nd er when next to replace the
brake fluid.
4.11 .13 Bleeding the brake system

Replenish supply pressure in com~ Place hose end in a jar half filled with
pressed~air system. b rake fluid.
Add brake fluid during the bleeding ope~ Depress brake pedar' and retain in this
ration to ensure that the brake fluid reser~ position.
voir (2 reservo irs in the case of two-circuit Back off bleed screw by approx. '/2rev-
brake systems) is filled to three fourths of o luti on and all ow brake fluid to flow
its capacity. o ut.
Tighten bleed screw and re lease brake
Bleed brake system with a bleeding de- pedal.
vice or by hand in the followi ng order: Repeat this sequence until the brake fluid
emitted from the hose is free of bubbles.
1. Master brake cylinder
Remove bleed hose, install dust cap.
2. Rear axle brake circuit (brake power Correct brake fl uid level.
regu lator, pressure control valve and Check brake booster piston stroke at 1 Bleed screws - master brake cyllnder
wheel cylinders) inspection pin (see section 4.11.4).
3. Front axle brake circuit (wheel cyl i n-
Fo r reasons of operational reliability,
ders)
exercise utmost care when bleed ing the
Remove dust cap from the respective brake system.
bleed screw.
Connect bleeder hose.

Box-type wrench
Bleeder hose

95

1 Moulding ring clamp screws
2 Headlight unit re1aining screws
1 Aiming screw (horizontal plane)
2 Aiming screw (verticat ptane)
96
4.12 Electrical system
4.12.1 12 V current collection on 24 V systems
On vehicles with a 24 V system c urrent for
12 Vequ;pment may only be coll ected via
a voltage d ivider.
4.12.2 Checki ng the headlight setting
Correct head light adjustment is of para-
mount importance to roadworthiness .
Periodic checks with a headlight adjuster
shou ld therefore be made.
Each headlight must be checked i ndivi-
dually. The other headJight and the other
exterior lights must be covered up for this
process.
Loaded vehicle an d vehi cles with air sus-
pension:
The bright/dark borderline of the low
beam is determined by subtracting 10 cm
(4 in) from the headlight horizon tal cen -
terline (distance between headlight cen-
4.12.3 Repla ci ng bulb in headlight and in turn signal l ight
Loosen headlight mounting sc rews.
Swing out headlight unit. Pull off cable
connector and remove lamp holder by
pressing down and turning left to remove
from bayonet lock. Remove twofilament
bulb with mou nting flange. Do n ot touch
new bulbs with damp or oily finge rs but
use tissue paper or some thing simila r.
Install the bulb in such a manner that
the mounting flange guide lugs engage
ter and ground) with the vehicle position-
ed in such a way that th e headlights are
10 m (32.8 ft) from the aim ing screen.
Unloaded veh icle :
(1 driver or 75 kg = 165 Ibs).
The bright/dark borderlin e of the low
beam is dete rmined by su bt racting height
30 cm (11.8 in) from the headlig ht hori-
zontal cen te rli ne (distance between
headlight cente r and ground) with the ve-
hicle positioned in such a way tha t the he-
ad lights are 10 m (32.8 ft) from the aiming
screen .
into the notches on the reflecto r neck.
Replace bulb holder by depressing and
turning it to the right until engaged . Plug
in cab le connector.
Replace bulb of turn signal ligh t and tight-
en headlight unit.
Then check headlight ad just ment. For
bulb specifications refer to " Technical
Data".
4.12.4 Three-phase alternator
Due to major differences in the operating
characteristics of the three-phase alter-
nator and the DC generator, the following
points have to be observed:
1. The three-phase alternator must never
be disconnected from the batteries
while the vehicle is in operation. As
long as the engine is running, neither
an alternator cable. nor a battery ter-
mi nal clamp must be loosened,
removed or wrongly connected.
2. Tow-start the vehicle only with the bat-
teries connected.
4.12.5 Fuses
All points of connection must be in posi-
tive contact with each other. For return of
the current, make sure all power consum-
ing units are well grounded. Damaged
cables must be insulated by means of in-
sulating tape.
Faulty fuses must be replaced instead of
repaired . An additional set of 1uses and
bulbs should always be carried in the ve-
hicle for emergencies.
3. Only after the positive and negative
cables have been removed from the
terminal posts may the batteries be
charged by means of a rapid charger.
4. For welding jobs with the electric
we lder, connect the ground term inal
of the welder directly to the part to be
welded. Detach positive and negative
terminal clamps .
5. Repairs and inspections on the alter-
nator are to be performed by the skill-
ed staff members of a MERCEDES-
BENZ service station only.
1 Lamp - turn signal
2 Lamp - parking light
3 Lamp - headlight
4 Lamp - socket
Besureto remove the cause of a burnt out
fuse prior to rep lacing the fuse.
Prior to perform ing work on the electrical
system , the negative (-) battery terminals
must be disconnected from the battery
posts. Objects liable to conduct electri-
city (tools) must not be placed on top of
the batteries because they might cause
shorts.
97
 Fuse box I
No. Consuming component
1 Hi gh beam , left; high beam indicator light
2 High beam. right
3 Low beam , left
4 Low beam, right
5 Stop li ght sw itches I and 11; switch. exhaust brake ; back~up light
6 2nd starter Switch (engine); horn
7 Gearshift range selection
a Tu rn signal system
9 Windshield wiper
10 Blower
11 Instrument cl uster, tachom eter, indicator lights, buzzer
, Locking spring - fuse box (10 open, move back-
wards) 12 Heated outside mirror and mirror control

Fuse box 11

No. Consuming compone nt

• Do not connect any add itional consum ing compo-
nents.
13 Tail light, left; parking light, left; clearance lights
14 Tail light, right; parking light, right; electronic charging ba lance
15 Lighting , heater control; lighting , push button switch
16 Gearshift range selection dimm ed indicator light, headlight washer system
17 Tachog raph , clock
18 Radio
19 Haz ard warning flasher system
20 . Plug socket , cab light
21 Fog ligh ts
22 Electronic charging balance (se ries res istor)
23' Tail light, right , 12 V; stop lights 12 V
24* Tail light, left, 12 V; switch, exhaust brake, 12 V

98
Fuse box 111
No. Consum i ng component
25 Refrigerator
26 Supplementary heater

;~)
29 Reserved for optional extras
30
31
32 Seat heater

;!}
35 Reserved for optional extras
36
Fuse boxes I, 11 and III
1- 36 Fuses
Spare fuses are located in the fuse box (with data card 5).

99
 4.12.6 Battery care

Checking the speci fic gravity
1 Hydrometer
Clean batteries only with the plugs
screwed in. No gasoline, benzol , kero·
sene or sim ilar should be used for clean·
ing. Lightly coat terminals with acid-
proof grease, particularly clamp under-
side. Vent holes in the plugs and/or cell
ventilation hoses must not be plugged.
No metal objects should be placed on the
batteries (danger of short circuit). Battery
visual inspections must never be per-
formed with naked lights because the
formation of Qxy·hydrogen gas might
create the danger of an explosion . Only
use electric lights.
The electro lyte level in each cel l should
be approx. 15 mm (0.6 in) above the plate
upper edge. Replen ish on ly with distilled
water. Water evaporates while the battery
is charged duri ng vehicle operation. No
metal funnels must be used for replen-
ishment. The electrolyte specific gravity
gives a rough indication of the battery
state of charge. Replace drained electro·
Iyte by chemically pure battery acid of the
like specific gravity. For charging , remove
terminals. The charging current should
not exceed 110 of the battery capacity . The
battery can be considered charged as
soon as all cells produce gas uniformly
and vigorously.
Caution! Be sure to check the electrolyte
level at least once every week in summer
and during the hot areas.

100
4 .13 Chassis

4.13.1 Checking and servicing the trailer coupling

The trailer coupling must be checked for
longitudinal free play daily. The following
additional maintenance services are re-
quired periodically (observe manufactur-
er's instructions):
1. Once a week, thoroughly clean and
grease the trailer coupling and check
the coupling rod mount.
2. Check for tight seating and retighten,
if necessary, the coupling rod final nut
and the securing bolts of the trailer
coupling.
Adhere to torque specifications.

4.13.2 Checking and servicing the fifth wheel coupling

The following services are to be perform-
ed on the fifth wheel coupling periodically
(observe manufacturer's instructions):
1. Disconnect the semitrailer from the
tractor once a week.
Clean and coat with multipurpose
grease lower fifth wheel plate with
kingpin lock and upper fifth wheel
plate with kingpin. Grease all lube
nipples.
The kingpin must snugly fit the kingpin
lock. Check by shaking vigorously to-
ward all sides. Maximum permissible
longitudinal play between kingpin and
kingpin lock must not exceed 2 mm
(0.08 in).
2. Inspect for dis tortions the fifth wheel
coupling attachment, upper fifth
wheel plate and kingpin.
3. As an additional item of maintenance,
the entire fifth wheel coupling must be
cleaned every six months.

101
4.14 Vehicle cleaning and care
Use an ample supply of water to wash the
vehic le.
Do not wash it in direct sunlight. Use dry-
cleaning gasoline (not automotive fuel ) to
remove grease stains. Do not apply cru de
oi l or grease 10 the synthetic resin finish
since such agents will quickly destroy the
protective film on the finish.
Brush down heavily soiled aluminium
drop sides with water to which a non-al-
kaline detergent may be added.
For cleaning steering wheel, gearshift le-
ver, soiled upholstery and floor covering
in the cab, use only warm water with dish
washing detergent or wash ing powder for
delicate fabrics. Do not use scou ring
agents.
. Use dry-cleaning gasoline to remove
grease stains in the upholstery.
102
Clean seat be lt webbing with lukewarm
water and soap . Do not apply any chemi-
cal cleaning agents. Do not dry the web-
bing at temperatures above 80° C/176° F
or i n direct sunlight. Never bleach or re-
dye the webbing .
Apply some talcum to window weather-
strips and door rubber seals.
Have the chassis thorough ly cleaned and
inspected prior to the performance of ma-
jor maintenance work.
After cleaning the vehicle , especially if
steam cleaners or grease solvents were
us ed, lu bricate chassis acco rding to the
lubrication points-summary.
All chass is components and the under-
section of the driver's cab are exposed to
outside influences (stones, gravel) and
chemical reactions (melted snow, thaw-
ing salts).
Repair damaged parts and corroded
spots , th en touch up the paintwork and, if
required, perform al l welding prior to the
application o f corros ion inhibitor. The
use of aerosols, such as pet roleum, diesel
oil and the like, should be discontinued.
Information on tested and recommended
anti-corrosion compounds can be
obtai ned from any MERCEDES-BENZ
service station.
Brake hoses must never be pa inted or
cleaned with gasoline, benzo l, ke rosene
or mineral oils. Clean hoses on ly w ith wa-
ter. Be sure not to apply any sprays or
grease to the brake hoses when spraying
or lubricating the vehicle.
4.15 Preparing the vehicle for storage
- Thorough ly cl ean the interior and exte·
rior of th e vehicle and park it in a dry
and airy garage.
Grease all lubricating points in accord-
ance with specifications in the mainte-
nance booklet.
Increase tire pressure by approx. 2 bar
above the specified level to preven t flat
spots on t he tires.
- Cover up tires to protect against sun
rays.
Fill up fuel tank completely.
Drain condensation from the air tanks.
Check coo lant for antifreeze content. If
the vehicle is operated without anti·
freeze in the coolant (e. g. in tropical
zones), it will do to add 1% anticorro-
sio n oil.
4.16 Preparing the vehicle for service after storage
The following points must be observed
when a laid-up vehicle is put back into
service:
Inflate tires to specified pressure.
Renew brake flu id if it has not been
rep laced for one year or if the storage
period of the vehic le is unknown.
Check paintwork for damage and re-
pair.
- Spray chassis with undersea!.
Should the vehicle be laid up for an
extended period, spray pa intwork and
chromium-plated parts with wax in-
ten ded for outer skin protection.
Position wheel chocks prevent the ve-
hi cle from rolling away.
Release hand brake.
Detach negative battery terminals.
Ope rate supplementary heater and air
conditioner once a month for approx.
10 minutes.
Regularly service batteries which are not . Should the 500-1500 km/300-900 miles
i n use. Coat terminal posts with acid-
proof grease. Recharge batteries once a
Shou ld the engine have been pre-
served, perform special depreservation
measures. Every MERCEDES-BENZ
service station will inform you accor-
dingly.
Check oH levels in engine, steering
gear, transmission and live axles.
- Check coolant level and antifreeze
effect.
month or charge continuously with
0.06 A. Discharge and recharge every
3 months. Check electrolyte level. Battery
service li fe , however, is limited, no matter
how well batteries are serviced.
Drive vehicle for app rox. 1 hour every
3 months. If this is not feasible, run engi-
ne at moderate speed for approx. 1 hour.
Engine, fuel system etc. can also be pre·
served for extended periods. Every MER·
CEDES-BENZ service station will readily
advice you.
Change engine oil and filter according
to maintenance booklet specifications. '
inspection have not been carried out yet,
use initial operation oil.
Connect batteries.
- Function-test electrical system .
- Start eng ine and check oil pressure.
Inspect hoses and lines for cracks and
leaks.
- Check brake efficiency.
103
5 Troubleshooting

Thefollowing suggestions will help you to following suggestions are to facilitate function. These recommendations are
cope with roadside failures. It is their pur- troubleshooting. They are not intended to not to be considered complete.
pose to enable you to drive your vehicle to substitute the work of the expert who will
a MERCEDES-BENZ service station. The eventually eliminate the cause of the mal-

5.1 Engine and fuel system For details

re1er
Cause Corrective action to section
Engine will not start Fuel tank almost or completely 2.1
empty Fill up and bleed the system 4.3.5
4.3.1
Fuel line, fuel tank strainers 4.3.2
or precJeaner clogged Clean and bleed the system 4.3.5
Clogged fuel fi lter Renew filter elements, 4.3.3
bleed the system 4.3.5
Fuel system leaking Seal the fuel lines and the precleaner,
bleed the system 4.3.5
Ambient temperature below Observe w inter operation 2.10
+32 0 F W C) instructions 3.1

Hard starting or engine stalling Clogg ed fuel filter Renew filter elements, 4.3.3
bleed the system 4.3.5
Fuel tank vent restricted Clean the breather
Overflow valve in the injection pump
does not hold the developed pressure Workshop responsibil ity
Lack of power Unsuitable fuel Dra in and replace by branded fuel 2.1 /3.1
Observe winter operation instructions 2.10

104
 For details
refer
Cause Corrective action to section
Lack of fuel Clean or renew filter elements 4.3.3/4.3.5
Full-load stop is not reached Adjust full-load stop, consult workshop -
Insuffici ent air supplied
at high engine speeds Service air cleaner 4 .2.2
4.2.3
Exhaust brake t hrottle valve
partially closed Workshop responsibility
Black exho ust sm oke Air cleaner obstructed Service 4.2.2
4 .2.3
Faulty injection nozzles Workshop responsibil ity
Start of delivery improperly adjusted Workshop responsibil ity
Excessive quantity of fuel injected Workshop respons ibil ity

Eng ine overheats Not enough water in the cooling system
Faulty thermostat
Loose or broken V-belts
Cooling system clogged
Exterior of radiator soiled
Fluid coupling of fan
defective
Unusual engine nois es Bearing in exhaust
turbocharger defective
Add water, check system for leaks 2.1
Replace thermostat
Retighten or renew V-belts 4.4.4
Workshop responsibility
Clean exterior of radiator 4.4.2
Lock fluid coupling , renew fan after
a rryaximum of 1000 km (600 miles) 4.4.3
Workshop responsibil ity

5.2 Clutch

Clutch slips Clutch fac ings worn or covered

with grease or oil Workshop responsib il ity

Cl utch dragging Air in the Check system for leaks, 2.1

hydraul ic system replenis h, bleed 4.5.2

105
 For details
refer
5.3 Steering Cause Corrective action to section

Hard steering No oil in steering gear Check steering gear for

(Manual steering) leaks, ref ill w ith oil 4.9.2

Hard steering Low fluid level in the system Check system for leaks,
(Power steering) add fluid 4.9.2
Air in hydrau li c system Check system for leaks,
add fluid 4.9.2
Filter restricted Replace fi lter element 4.9.2

Power steering Filter clogged Replace filter element 4.9.2

rattles when being turned Air in the hydraulic system Check system for leaks, refill with oil 4.9.2
Lack of oil in the system Check system for leaks, refill with oil 4.9 .2

Poor centering Steering knuckles not lubricated Lubricate

Tires under-inflated
Incorrect toe-in
Improperly adjusted front wheel
bearings
Excess ive free play (power steering)
Low oil level
Air in the hydraulic system
Inflate to correct pressu re
Correct 4.9.3
Workshop responsibility
Workshop responsibility
Check system for leaks, refill with oi l 4.9.2
Check system for leaks, refill with oil 4.9.2

5.4 Brake system

Warning light comes Caution! Stop at once! Observe duplex pressure gauge,
on during operation No or insufficient brake pressure increase supply pressure,
check brake system for leaks,
if necessary 2.1

106

No or insufficient
braking action
Uneven braking action
Supply pressure cannot be built
up at all , or not fast enough
For del ails
reler
Cause Corrective action to section
No supply pressure Observe brake pressure gauge,
increase supply pressure,
check brake system for leaks , 2.1
if necessary, and check
governor and ai r co mpresso r
Air in the hydraulic brake cont rol Check system for leaks, 4.11 .11
system replenish , bleed 4.11.13
Fluid level in hydraulic brake con trol Check system for leaks, 4.11.10
system too low replen ish , bleed 4.11 .1 2
4.11.11
4. 11 .13
Binding brake shoes Remove brake drums,
free up anc horag e
Binding brake shaft Grease, free up, if required
Worn or greasy linings Have bra kes relined
in workshop
Worn tires Exchange 4.1 0.4
Tires under-inflated Inflate to correct pressure
Brakes improperly adjusted Adjust 4.11.5
Oil on brake lin ings Reline brakes , clean brak e drums
(workshop responsibil iti es)
Uneven brake tining wear Reli ne brakes
(workshop responsib ility)
Faulty hydraulic system Workshop responsibility
Air vol ume supp lied by compressor
is insuffi cie nt Fun ction-test co mpresso r
Governor lets off air Have gove rnor rep laced or
constantly repaired in workshop
107
 For detai ls
refer
Cause Corrective act ion to section

Compressed-air system leaking Check for leaks, seal,

if required 2.1

Braking action not controllable Brake shoe pivoting points stiff Remove brake drums,
by amount of pressure applied free pivoting points
to brake pedal Faulty wheel brake cyl i nder Workshop respo nsibil ity

Hand brake will not release
S.S Electrical system
No or insufficient supply
pressure in the hand brake circuit
Check system for leaks 2.1
If required - for towing
purposes only - release spring-
loaded brake cylinder manually
or pneumatically 4.11.9

Starter will not crank the engine Battery flat Recharge 4. 12.6
Battery defective Replace 4.12.6
Battery terminals loose or corroded Clean terminals, coat with acidproof
grease, tighten firmly 4.12.6
Cable loose or faulty Tighten or replace
Starter defective Workshop responsibility

Key of steering lock cannot Battery master switch Switch on battery master 1.9
be withdrawn switched off switch
Batteries discharged or damaged Recharge or renew 4.1 2.6
Electrical system faulty Consult workshop

Generator charging control light Burnt-out bulb Replace

will not come on (with engine shut Open circuits in wiring Tighten connections or replace wiring
off)

Generator charging control light Regu lator or alternator faulty Workshop responsibil ity
remains on (with the engine running) V-belt loose or broken Retighten or renew V-belt 4.4.4

108
 For detai ls
refer
Cause Corrective action to section

Oil level warning light will not Burnt-out bu lb Renew 6.14

come on (engine stopped) Connections fau lty/loose Tighten or renew

Oil/evel warning light will not Oil level too low Rep lenish oil 2.1
go out (engine running) Defective contact switch
(sending unit) Workshop respons ibil ity

5.6 Supplementary heater

Heater will not Ignite Fuel tank empty Refuel 2.1

Battery flat Recharge 4.12.6
Ambient temperature below Comply with measures required 2.10
32' F (0' Cl for winte r operation 3.1
Fue l pump will not feed Wo rkshop responsibility

Heater is switched off by the Coolant level too low Check system for leaks ,
thermostatic switch replenish coo lant 2.1
Heater motor will not start Fuse defective Renew fuse
Commutator or carbon brushes worn Wo rkshop responsibility

109
 5.7 Maneuvering and towing
The front coupling jaw is provided for the
maneuvering of trailers and for being
towed.
For towin g, leave engine run ni ng, if pos-
sib le, to allow the power steering to be-
come effective and to supply com-
pressed air to the brake system.
Note: In case supp ly pressure is lost in the
compressed-air system , release spring-
loaded brake cylinder me cha nically or
pneumatically. See sect ion 4. 11.9.
Planetary hub reduction 8)(le
Removing a)(le shafts
, Pliers
. In the event of engine damage
Towing distance up to 100 km (62 mi les).
Vehicles equipped with transmissio ns
G 3/50 (714.0), G 3/60 (7 14.0)
There are no restrictions for towing the
vehic le.
Veh icles equipped wi th transm ission
G 3/90-8 GP (71 4.3), G 3/65-9 GP (714.2)
1. Move gearshift lever to gate between
5th and 6th gear.
Shou ld the speed range indicator light
H on the instrument panel fail to come
on , remove propeller shafts to the live
axles.
11 0
2. On all wheel drive vehicles , engage
road operation posit ion of transfer
case.
3. Do not exceed towing speed of
60 km/h (37 mph)
Towing distance more than 100 km (62
miles)
Remove propeller shafts of live axles.
There are no restrictions for towing the
veh icle.
In case of transmission demage
Remove propeller shafts of th e live axles.
In case of rear axle damage
Planetary hub reduction axle:
1. Remove covers of planetary hub re-
duction gears.
2. Remove snap rings with pliers (on-ve-
hicle tools).
3. Remove axle shafts (by using special
tool or an M8 bolt of 120 mm [4.8 in]
length).
4. Reinstall covers.
Hypoid type axle:
Remove axle shafts.
Cover up openings so the bearings will
not be dirtied.
On all-wheel drive vehicles, in addition
remove propeller shaft from front axle to
transfer case.
In case of front axle damage
Lift front axle
On all-wheel drive vehicles , in addition
remove propeller shaft from rear axle to
transfer case.
A bogged down vehicle whose drivi ng
wheels have dug into soft or muddy
ground, should be towed out with utmost
care, espec ially when the vehicle is load-
ed.
The vehicle must not be pulled out jerkily
or at an angle - especially sideways - be-
cause the chass is of the vehicle might be
damaged. Never pull out a vehicle to-
gether with the trailer.
A useful piece of advice: using the rear
coupling jaw, pull the vehicle out back-
wards along its original traCk, if possible.
Planetary hub reduct ion ulc
Removing 3)(le shaHs
1 Special tool
111
6 Technical data
6.1 Data cards/Identification plates

1 Chassis number on RH side menber Engine No. Iden tification plate (chassis number,
on crankcase on RH side permissible weights)
2 Body No.
With the veh icle you are handed over data cards listing all the important vehicle data
(e.g. chassis number and component numbers in cluding models and designations of
the special equipment, etc.). These data are required when ordering spare parts or
inq uiring for tech nical details.
Card No. 1
For safety reasons this card must not be kept in the vehicle. It lists the key number for the
ordering of replacement keys.
Card No. 2
Thi s card (without key number) is kept il1 the maintenance booklet.
Card No. 5
This card (wi thout key numbers) is located on the fuse box cover.

112
 6.2 Engine
1013 1017
1213 1217 .
1413 1417
Vehicle. 1613 1617
Engine 352 X 352 A. V
Model 353.94. 353.95.
Method of operat ion Diesel four stroke
Cyl i nder arrangement .......•. 6 cylinder, vertical in line
Bore .. . 97 mm (3.8 in.)
Stroke 128 mm (5.04 in .)
Total displacement 5675 cm 3 (346 cu.in.)
Compression ratio, approx 17 16
M in. compression pressure
(engine warmed up) . . 19.6 bar (284.5 psi)
Deve loped horsepower according
to DIN 1 ..... 96 kW (130 HP) 124 kW (168 HP )
Max. torque in Nm (lb-ft) ... . 363 (267) 490 (362)
at 2000/min at 1600/min
Rated speed. 2800/min
Idl ing speed 600/ min
Injection orde r 1 - 5-3-6-2 - 4
Ejectio n pressure of injection nozzles
Setting data . ........... ... ...... . 200 + 8 bar (2901.6 + 113.8 psi)
Start of delivery (basic setting) Toe
18° before 21 0 befo re TDe
Valve arrangement . ........ . overhead, per cylinder 1 intake and
1 exhaust valve
I The specified output measured according to DIN Valve clearance w ith cold engine
70020 Is actually available at the clu tch lor the propul· Intake valves 0.20 mm (0.008 in .) 0.25 mm (0.010 in.)
sion of the vehicle since all power requ irements for
the 8u)o(iIlary units are deducted . Exhaust valves 0.30 mm (0.012 in.) 0.40 mm (0.016 in.)

113
 Lubrication system Force·feed lubrication
Oil pump ........ . . Gear type pump
Oil cooling Heat exchanger
Oil filter. Paper full-flow filter
Oil pressure
Operation (at max . rpm) at least 2.5 bar (35.5 psi)
Idling speed .. ... ... . . at least 0.5 bar (7.11 psi)
V·belt
Three·phasealternator . 12.5 x 1450
Power steering pump . . . 12.5 x 975
2 nd air compressor . .. . ... .. .. . . . . . 12.5 x 1000

6.3 Cooling system Type . .................. .. .. Water circulation cooling

Temperature control Thermostats
Coolant temperature 158- 203 F (70 - 95 C)
0 0

6.4 Clutch Design ......... . Single plate dry type clutch

Clutch actuation . . Hydraulic

6.5 Transmission Vehicle . .. .. . . .. ... ... .... . .... . . .
Design . . ........ .
Model ..... . . . .... .. . ...... . . .
Vehicle . .
Design .. ........ . ....... . .. . . .. .. . .
Model .................... . .
1 013/K. 1 017/K/SI AI AKI AS/KO/FI AF/LS.
1217/K/SI AI AKI AS/KO/L/LS.
1417 A/AK/AKO. 1617 AK (series)
1013 S. 1213 (optional)
Synchromesh transmission G 3/60-5/7.5
714.0 ..
1013 S/KOI AI AK.
1213/K/S/KOI AIAKI ASI AKO.
1413/KOI AI AKI AKO. 1613/L (series)
1013/K. 1017/A. 1213/K. 1217/A. 1413/K.
1417/K. 1613/KO. 1617/K/KO (optional)
Synchromesh transmission G 3/50-5/8.5
714.0 ..

114
Ve hicle . . .... . ...... . . .. .. ... .. . 1417/KO , 1613 KO, 1617/KO/L (series)
1013/K/S/KO/, 1017/K/S/KO/F/LS,
1213/K/KO , 12171 A/K/S/KO/L/LS,
1413/KO , 1613/L (o p1ional)
Design . ... . .. . . ... . . . .... . . . .. . Synchromesh transmiss ion
G 3/90-8/9.29 GP
Model. 714.3 ..
Vehicle . .... ....... . ........ . 1413 K, 1417 K, 1613 K, 1617 K/S (series)
1013KO, 1017, 1213KO, 12171 A/SIAKI AS ,
1413 A, 1417/A/AK/AKO, 1613 KO,
1617 KO/AK (optional)
Design. Synchromesh transmission
G 3165 - 9/13.36 GP
Model 714.2 ..
Number of gears G 3/50-5/8.5 := 5 forward , 1 reverse
G 3/60- 5/7.5 := 5 forward. 1 reverse
G 3/90-8/9.29 GP := 8 forward , 1 reverse
G 3/65-9/13 .36 GP := 9 for ward, 1 reve rse
Gear rat ios . G 3/50-5/8.5
i ~ 8.41914.4712.581/1.556/1.0;
Reverse = 7.771
G 3/ 60-5/7.5
i ~ 7.508/3.986 /2 .302/1.38711.01;
Reverse = 6.932
G 3/90-8/9.29 GP
i ~ 9.294/6 .648/4.836/3.62/2. 56711 .836/1.336/1.0;
Reve rse = 10.4
G 3/65- 9/ 13 .36 GP
i ~ 9.294 / 6.648/4 .836/3.62/2 .567/1.836/1 .336/1 .0;
Crawler = 13.36
Reverse = 12.0

115
6.6 Transfer case Vehicle 1013 A/AK, 1213 AlAK/AS/AKO,
1413 A/AK/AKO,
1017 A/AK/AS/AF, 1217 A/AK/AS
Design . . . .. . . . ........ , .. . VG 500 - 3 W/1.64 with differential lock
Model ........ . . .. . .. . . .. . 750.5 ..
Gear ratios . . ... . .. . .. ........ . . . i ~ 1.045/1.64

Vehicle. 1417 A/AK/AKO, 1617 AK

Design VG 500-3 W/1.85 with differential lock
Model 750.5 ..
Gear ratios .. i = 1.045/ 1.85
Optional:
VG 850 - 3 W/1 with differential lock
Model ..... . .. . . 750.4 ..
i = 1.0

6.7 Steering system Vehicle 1 013/K/S/KOI AI AK/LS,

1017 IK/S/KOI AI AKI AS
Design Manual steering L 5 Z
Model. 760.4 ..
Optional:
Power steering LS 5 F
Model .......... . 765.2..

Vehicle . 1017 FI AF, 1213/K/S/KOI AI AKI ASIAKO,

1217 IK/S/KOI AI AKI AS/L/LS,
1413,1417, 1613/L, 1617/L
Des ign Power steering LS 5 F
Model. 765.2 ..
Optional : 1613/L, 1617/L
Power steering LS 7 F
Model 765.3 ..

116
6.8 Front axles Vehicle .. ... ... . ... . ... , ... , ..•.... 1 013 / K/S 1017/ K/ S/LS
(Gear ratios refer to Des ign. . . . ..... .. .. . •... .. ... . .. • .. Rigid knuckle-yoke axle VL 217-3.6
identification plates) Model .... ... .... . __ . . . . . . __ _ . . . 730.8 ..
Optional:
Rigid knuckle-yoke ax le VL 3/6-4 .1
Model. 730.0 ..

Vehi cle .... . . . .. . .. . . • ........ . .. .. 1013 KO, 1017 KO / F,

1213/K/S/KO, 1217/K/S/KO
Des ign. . ....... .. ....... , .. .. . . Rigid knuckle-yoke axle VL 3/6-4 .1
Model . .. .. . . . ..... . . . . 730.0 ..
Optional:
Rigid knuckle'yoke axle VL 3/7-5
730.0 ..

Vehicle . . . . 1217 LlLS, 1413/K/KO, 1417/K/KO

Design . .. . Rigid knuckle-yoke axle VL 3/7-5
730.0 ..
Optional:
1413/K/KO, 1417/K/KO
Rigid knuckle-yoke axle VL 3/7 0-5
730.0 ..
Rigid knuck le-yoke axle VL 3/8 D-S.S
730.0 ..

Vehicle . ........ . .....• • . .... 1613/K/KO/L, 1617/K/KO/L

Design . .. " ..........• •..... Rigid knuckle-yoke axle VL 3/8- 6.5
Model .. .. . .. .. . .. .. . •• ... . . . . . ,. 730.0 ..
Optional:
Rig id knuckle-yoke axle VL 3/8 0-6.5
730.0 ..

117
 Vehicle . .... • • . 1617 S
Design. Rigid knuckle-yoke axle VL 3/8 0-6.5
Model 730.0 ..

Vehicle 1013 A/AK, 1017 A/ AK/ AS/ AF,

1213 AlAK/AS / AKD, 1217 AlAK/AS
Design .. ....• •. . .... ...... • • . Pall aid axle AL 3/7-4.3
Model .. 731.3 ..
Optional:
1017 AlAK, 1217 A/ AK/ AS
Palloid axle AL 3/6 (5) '-6
731 .6 ..
1213 AlAK/AS/AKD
Pall aid axle AL 3/6- 6
731 .6 ..

Vehicle. 1413 AlAK/ AKD , 1417 AlAK/ AKD ,

1617 AK
Design. Pallold axle AL 3/6- 6
Model 731 .6 ..

Toe-in (measured on the wheel flange)
Camber .
Kingp in inclination
Caster . .. ... ... ... • ..
straight tie rod 0 ± 0.5 mm (0 ± 0.012 in.)
offset tie rod 0 ± 1.5 mm (0 ± 0.059 in.)
1"
Rigid k nuckle-yoke ax les "" 5"
Palloid axles "" 91> 30'
Rigid knuckle-yoke ax les = 2" 40'
Pallo id axles = 1" 40 '
Camber, caster and kingpi n inclinati on
tolerances shall not exceed ± 20 ' de-
grees of angle.

IS}' Optional extra: Wi th dilterenl ial lock

118
6.9 Rear axles Vehicle . .. . . ....... . . . . . ...... . . . 1013/K/S/KO/A/AK
(Gear ratios, refer to 1017IK/S/KOI AI AKI ASI AF/F
identification plates) 1213/K/S/KOIAI AKI ASI AKO
12171 A/K/KOI AKI AS/S
Design . ... .. . ... . , . . . .. .... . .. ... . . Hypoid gear axle HL 4116 (5)'-7.7
Model .... .. . ... .. ... .••... . ... . ... 744.3 ..
Optional: extra:
Hypoid gear axle HL 4/17 (8)1 _9.2
744.4 ..
10171S/F, 1217 IS
Hypoid gear axle HL 4/01 (8 )'_
745.6 ..
1217 S
Hypoid gear axle HL 4/8 (8)1-10
744 .5 ..
1017 K/A/AK/AS/KO
1217 K/A/AK/AS/KO
Planetary hub reduct ion axle
HL 7/1 (5)'-10
740.1..
1017 LS
Hypoid gear axle HL 4/01 L (5)'-10
745.6 ..
Hypoid gear axle HL 418 L (5) '- 10
744.5 ..
1217 L/LS
Hypoid gear axle HL 4/01 L (5) '-1 0
745.6 ..
Hypoid gear axle HL 418 L (S) '-10
744.5 ..
Planetary hub red uction ax le
HL 7/1 L (5) '-10
740.1..
(5 )' Optional: with dilferentiallock

119
 Veh icle . ... . ... . .. . •.... 1413/KO/ AlAKO
Design. . . ... . .. . .. . Hypoid gear axle HL 4/17 (5)'-9.2
Mo de l .... .. ... .. ... . . . . . 744.4 ..
Optional extra :
1413/ A
Hypold gear axle HL 4/8 (5) '-10
744.5 ..
1413
Hypoid gear axle HL 4/01 (5 )'- 10
745.6 ..

Vehicl e 1413 K/ AK, 1417 K/ AK/ A/ KO/ AKO

1613 K/ KO , 1617 K/ AK/ KO
Desig n . . . . .. . . . . . . . . . . .. .• . . . . . ... Planetary hub redu ction axle
HL 7/1 (S) '- 10
Model . .... . .... . .. . . . .. • . . ... 740.1..
Optional ext ra :
Pl anetary hub reduction axle
HL 7/1 D (5)'- 10
740.1..

Vehicl e 1417, 1617

Desig n . Hypo id gear axle HL 4/01 (S)'- 10
Model 745.6 ..
Optional extra :
Hypoid gear ax le HL 4/01 D (5)'-10
745.6 ..
1617
Hypo id gear axle HL 4/06 D (5)'- 12
745.6 ..
Planetary hub redu ction axl e
HL 7/1 D (5)'-10
740.1 ..

(5)1 Optional: with d ifferential lock

120
 Vehicle . ... . . . •............. . . .. ... 1613
Des ign . . , . Hypo id gear axle HL 4/8 (S)'-1 0
Model ... 744.5 ..
Optional extra:
Hypo id gear axle HL 4/01 (S)'- 10
745.6 ..
Hypoid gear axle HL 4101 0 (S) '-10
745.6 ..
Vehicle . . 1613 L
Design . Hypoid gear axle HL 4/8 L (S)'-10
Model ..... . .• •. . . . . .. . .... .• ... . .. 744.5 ..
Opt ional extra :
Hypoid gear axle HL 4/01 DL (5) '-10
745.6 ..
Vehicle 1617 L
Design . . . Hypoid gear axle HL 4/01 L (S) '-10
Model .. 745.6 ..
Optional extra :
Hypoid gear axle HL 4/01 DL (5) 1- 10
745.6 ..
Hypoid gear axle HL 4/06 DL (5) '-1 2
745.6 ..

(S)1 Optional: with different ial lock

121
6.10 Air suspension
Air suspension system

~1 7.3 5.1 381 8.1 384 26.4 8.1 4~3 .43.1 28.1

, A = B

A <= Supply pressure

B = Air suspension pressure
For further legends, refer to page 130

122
Air suspension system (truck tractor)

1.1 7.3 5.1 J8.2 38.4 26.4 42~ 43.1 28.1

I
J

(~ - - :j
J

~1 4.4 38.2 42.7 &1 33.1

=_ A liIC:Oiil B

A = Supply pressure
8 = Air suspension pressure
For further legends, refer to page 130

123
6.11 Brake system
Two-circuit hydraulic brake with two-circuit compressed-air assistance (vehic les without air suspension)

35.0 33.1 20.1 10.2 1.1 20.1 25.2 38.3 8.1 23.3 19.3 10.1 28.1 16.1 38.3 24.1 38.3 38.2 35.5 35.2

14.2 11.2 33.1 19.5 2.1 4.4 38.2 10.1 5.1 5.2 8.1 38.2 20.5 19.5 26.3 38.2 18.5 17.1 35.3
A = 8 = c _ 0
A Supply pressure
B Brake pressure
C Control line for spring-operated
hand brake , single-line and two -li ne
tra iler brake system
o = Hyd raul ic line
For fUrther I ~gends , refer to page 130

124
Two-circuit hydraulic brake with two-ci rcuit compressed-air assistance (truck tractor without air suspension)

35.0 14.2 20.1 10.2 1.1 20.1 8.1 VII VIII VI Z3.3 10.1 28.t 16.1 38.3 19.5 Z6.3 38.2

11.2 33.1 19.3 33.1 19.5 3B.3 2.1 4.4 3B.2 10.1 5.1 19.3 3B.2 5.2 B.l ZO.5 38.2 18.5 17.1

=A = 6 = c _ 0

A Supply pressure
B Brake pressure
C Control li ne for spring-operated
hand brake, single-li ne and two-l i ne
trailer brake system
o = Hydraulic line
For further legends , refer to page 130

125
Two~circuit hydraulic brake with two-circuit compressed-air assistance (vehicles with air suspension)

35.0 20.1 10.2 1.1 20.1 25.2 3B.3 B.l 2.1 7.3 23.3 19.3 3B.2 B.l 3B.4 26.4 16.1 3B.3 10.1 2B.l 3B.2 35.5 35.:1.

14.2 11.:1. 33.1 33.1 5.1 33.1 30.1 4.4 3B.2 10.1 5.1 5.2 B.l 3B.3 19.5 20.4 38.2 38.:1. 18.5 17.1 35.3

= A = B = c - D
A Supply pressure
B Brake pressure
C Control line for spring-operated
hand brake, single-line and two-line
trailer brake system
o = Hydraulic tine
For further legen ds, refer to page 130

126
Two-circuit hydraulic brake with two-circuit compressed-air assistance (truck tractor with air suspension)

VIIi VII B.l 23.3 7.3 19.5 38.3 10.1

11.2 14.2 33.1 33.1 19.5 20.1 2.1 4.4 3B.2 10.1 19.3 5.2
\
B.l 3B.3 16.1 2B.l 3B.2 20.4 3B.2 lB.5 17.1
= A = B = c ;:;;:::: 0
A Supply pressu re
B Brake pressure
C Control line for spring-operated
hand brake, single-line and two-line
trailer brake system
D = Hydraulic line
For furthe r legends , refer to page 130

127
Hydraulically controlled two-circuit compressed-air brake

35.0 14.2 20.1 10.2 1.1 20,2 38.2 8,1 25,1 33.2 13,2 38,2 8.1 16,1 22,1 25,3 26.1 38,2 35.5 35,2

11 .2 19.3 33,1 33.1 20.1 2,1 4.4 3B.2 10.1 5.2 3B.2 10.1 3B.2 2B.1 3B. 2 1B.5 17.1 35.3
~ A B = C
A = Supply pressure
B = Brake pressu re
C = Control line for spring-operated
hand brake, single-li ne and two-line
brake system
Fo r fu rther legends, refer to page 130

128
Hydraulically operated two-circuit compressed-air brake

35.0 20.1 10.2 1.1 20.1 20.2 8.1 VI VUI VII 13.2 16.1 38.2 22.1 28.1 38.2

14.2 11.2 19.3 33.1 33.1 2.1 U 38.2 10.1 5.2 38.2 8.1 10.1 38.2 18.5 17.1
._ _ · A = B = c
A = Supply pressure
B = Brake pressure
C = Control line for spring -operated
hand brake, single-line and two-l ine
brake system
For fu rther legends, refer to page 130

129
Legend for air suspension and brake systems

1.1 Air compressor 20.1 Control cyli nder 35.2 Automatic hose coupling
2.1 Governor with tire inflation 20.2 Diaphragm cylinder (two-line brake)
connectio n 20.4 Spring-operated cylinder 35.3 Auto matic hose coupling
4.4 Four-circuit protection valve 20.5 Spring-operated cylinder (two-line brake - brake pressure)
5.1 Compressed-air reservo ir 22.1 Spring-operated 35 .5 Automatic hose coupling
5.2 Compressed-air reservo ir diaphragm cylinder (single-line brake)
7.3 Charg ing valve w/o return flow 23.3 Two-circuit brake booster 38 .2 Test connection
8 .1 Check valve 24.1 Control valve 38.3 Test co nn ection
10.1 Electrical pressure switch (off) 25.1 Load/no- load valve 38.4 Test valve
10.2 Electrical pressure switch (on) 25.2 Press ure control valve 42.3 Air suspension valve
11.2 Duplex pressure gauge with 25.3 Pressure reduction valve 42.7 Control valve
brake pressure warning light 26.1 Automatic load-proportioning 43.1 Air suspension bellows
13.2 Two-circuit brake 'valve valve (mechanically contro lled)
14.2 Handbrake valve 26.3 Automatic load -proportion ing
(with testing position) valve (hydraul ic system)
16. 1 Relay valve 26.4 Automatic load-proportioning
17.1 Trailer co ntrol valve valve (hydrau lic system)
(single- line brake) 28.1 Two-way valve VI = Connection for hose coup lin g 35.3
18.5 Trailer control valve 30.1 Safety valve (two-line brake - brake pressure)
(two-line brake) 33.1 3/2-way valve (mechanically VII = Connection for hose coupling 35.5
Master cylinder controlled) (single-line brake)
19.3
19.5 Wheel cyli nder 33.2 3/2-way valve (electrically VIII = Connection for hose coupling 35.2
controlled) (two-line brake - supp ly pres-
35.0 Hose coupling (supply pressure) su re)

130
6.12 Electrical sy stem Three-phase alternator
Output .. . .. . . .... . 14V/55A
Optional extra:
28 V/27 A
Starter motor
Design . . Inertia gear-drive starter
Output. 12V/3kW
Optional extra:
24 V /4 kW
Batteries . 12V / 143Ah
Optional extra:
2 x 12 V/88 Ah or 2 x 12 V/110 Ah
1017 F/AF
2 x 12 V/110 Ah
Optional extra:
2 x 12V / 143Ah

131
Lamps (DIN 72601) incandescent lamps

Headlights . .. A12V45/40W
Optional extra:
H 4/12 V 60/55 W
Parking lights . HL 12 V 4 W

Interior lights . . . . .. .... • .......... }

Turnsignals,front.... . . ..... .. . . .... P 25-1112 V 21 W
Turn signals, rear. . . ..... . .. .
Stop tights ... . . .. . . .
Tai l lights . ........ .. ... . G 12 V 10 W

Side marker lights L 12 V 5 W (Festoo n bu lbs)

Instrument lighting .. ...... .

Brake pressure warning light
. ..
...
} H 12 V 2 W
Indicator lights. . ........ . .
Tachograph lig,hting
Maximum speed warning light ) 12 V 1.2 W (Glass-base lamp with cap)

Fuses ............. . ........ .. . 8 A DIN 72581

Example for 24 V system:
Headlights A 24 V SS/50 W
Optional extra:
H 4/24 V 75170 W
Parking lights . ....... . HL 24 V 4 W

etc.

132
Key to wiring diagram of supplementary heater (Long cab with battery master switch)

~".
b 1 Microswitch
1126 m
b 2 Switch
d 1-d 7 Relays
"' U
e l a, 16, 26 Fuses i l l4
m 1 Fuel pump
m 2 Starter
m 3 Supply unit
m 4 Heater blower motor
m 5 Coolant recirculation pump
n 1-n 5 Diodes
u 1 Contro l unit, a- d Relays
u 2 Timer
u 3 Heater
a Temperature fuse
b Con trol thermostat
c Thermostatic switch
d Heating coil
e Glow/ignition plug
f Ig nition spark generator
g Flame control thermostat
h Blower thermostat
X Connection , terminal 31 a,
tachograph
Y Connection , terminal 31 a,
battery master switch
P Test connection
A Plug connection , body
o Plug connection , roof
F Pl ug connection , chassis/cab
Standard equipment

133
Key to wi ring diagram, vehicle (1 2 V, pos. 1- 8)

F
M
,.
""
Connector,
Connector,
chassisfcab
engine
o Headlights
b 1 Combination switch
o Tr ans mission " Double H gearshift pattern"
b 13 Switch speed range
A .. Connector, cab
VG ,.. Connector, transformer behind cab b 38 Test connection starting lock d 2 Relay Ind icator lig hts
VD Connector, junction box, rear el _ e4 Fuses d 3 Relay
h 2 High beam indicator light e 7 Fuse
h 3 Headlight, left h 11 Indicator light speed range
Wire color code h 4 Headlight, r ight R. C. 1st 10 4th gear

bl
br
el
'"
..
blue
brown
ivory
o Fog lights
b 4 Pushbut10n swi tch
h 49

r 5
Indicator light speed range
5th to 8tll gear
Series resistor

ge ". yellow b 5 Plug socket

gn .. green d 1 Re lay
gr
Ii
..
..
grey
violet
h 5 Indicator light in switch b 4 [2] Turn sig nal lig hts
rs p ink b Combination switch
rt red [£] Brake syst em, backup light b
1
8 Trailer plug SOCket
sw "" black b 15 Hazard warn ing flasher Switch
ws '" white b 6 SlOp light switch e 8 Fuse
1 switch l-H drive
h 12 Indicator light In switch b 15
b Stoplight switch h 13 Turn signal Indicator light, tractor
Example 3 swi tches, R·H drive
h 14 Tur n signal light, right. on side
b 8 Trailer plug socket h 15 Turn signal light, right, front
Wire deSignation 1.5 grlrt b 9 Switch, backup light
h 16 Turn signal Ifgllt, right. rear
Cross saction of w ire 1.5 .. 1.5 mm 2 b 10 Switch, exhaust brake
h 17 Turn signal Ifght, left, on side
Basic colo r gr .. gray b 11 Switc,", for solenoid valve s 1
h 18 Turn signal tight, left. front
Indentiflcation color rt .. red e 5 Fusa
h 19 Turn signal tigh t, left . raar
h 6 Stop lighl, left h 2{l Turn signal indicator light, trailer
h 7 Stop light. r ight
r 1 Series resistor (locating light)
h 8 Warning light - hydreulic brake
u 3 Turn slgna~ sanding unit
control
h 9 Backup light
s 1 Solenoid valve, brake pressure,
[2] Power suppl y, starler conlro l fro nt axle
[!] WlndshJetd wipe r system
••2 Switch box
3
0 2
h 1
Batlery Change -over switch
Starter pushbullon
Charge Ind icator light
0 Horn, 2nd sta rter pushbutton
0 1 Combination switch
b 1 Combination switch
a _ on
b "" oH
m 1 Slarter 0 3 Switch, starting lock b 17 Foot-operated ~<; w i lch
m 2 Alternato r 012 2nd starter pushbutlon on eng ine e 9 Fuse
,"1
6
Batteries
Resistor 0 +
• 6 Fuse
h 10 Horn
m 3
u 4
Wlndshia!d wiper motor
Wiper pulse generator

134
, .J
L

"-- ----,,

"
L
Key to wiring diagram, vehicle (1 2 V, pos. 9-20)

o Heater
b 16 Switch, heater blower motor
h
h
h
26
29
30
Indicator light, PTO I and 11
Indicator light, dump body
Indicator light, hand brake
S Inlerior lights, tachograph
b 32 Swi tCh, interior light
e 10 Fuse h 31 Indicator light, inter-axle b 33 Switch, interior light
m 4 Heater blower motor d ifferential lock, fron l b 34 Switch, interior light
h 32 Indicator light, inter- axle b 35 Door contact switch
d ifferential lock, rear e 17 Fuse
1'1 33 Indicato r light, brake fluid g 3 Tachograph
(3 Operation monitoring equipment h 43 Instrument lighting
1'1 44 Interior light
b 19 Switch, 3rd brake circuit
b 20 Switch, buzzer, cooling water
temperature
G Extarlor mirror heater
h 45 Interior light
h 46 Interior light
b 14 Push button switch with indicator
b 21 Switch, dilferential lock, Iront axle
light
b 22 Switch, diflerentiallock,
1st reafaxle
b 23 Switch, dilferential lock,
e 12
r '2
Fuse
Exterior m irror heater, left G Rad iO

2nd reafaxle
r 3 Exterior mirror heater, right e 16 Fuse
p 1 Radio
b 24 Control switch, PTO I and 11
b 25 Control switch, dump body
b 26 Control switch, hand brake
G Parking light, left; clearance lights
b 27 Switch inter-a xle dilferential
lock, front
b 26 Switch, inter-axle dilferenlial
b
e
1'1
8
13
34
Trailer plug socke t
Fuse
Parking light, left
S Hazard warning flesher system
e 19 Fuse
lock, rear h 35 Tall light, left
b 29 Sending unit for brake fluid h 36 Clearanco light. left
b 30 Control switch brake pad wear
d 4 Relay
e l l Fuse
h
h
h
37
36
39
Clearance light, right
Marker light, lell
Marker light, right
G Plug socket
f 2 Sending unit lOT oil pressure b 36 Plug socket
gauge e 20 Fuse

f
Sending unit lor COOlant
temperature gauge
Sending unilfor fuel gauge
S Parking lig ht, right
b 8 Trailer plug socket Fog lights
g Instrument cluster e 14 Fuse
9 2 Tachom eter h 40 Parking light, r ight d 1 Relay
h 21 Instrument lighting, instrument h 41 Tall light, right e 21 Fuse
cluster h 47 Fog light. rig ht
1'1 22 Breke pressure warn ing light h 48 Fog light, left
h 23 Buzzer, monitoring coiling water
temperaturo and engine speed
h 24 Instrument lighling, tachometer
S Instrument panel IIghlln9
b 31 Dimmer switch, instrument panel r;;1 Electronic charging balance,
h 25 Indicator light, differential lock,
front axle lighting L.::.I trailer plug socket
h 26 Indicator light, differential lock, e 15 Fuse
1st rear axle e 16 Fuse e 22 Fuse
h 27 Ind icator light, differential lock, 1'1 42 Lighting for heater and venti lation e 23 Fuse
2nd rear axle control e 24 Fuse

136
 r----~~ ---- .;
~:P
, ._.9..... -
1,
,
j
' !'.

,
,,
127 121
'"
L
'" 123 124 125 126

"
137
Key to wiring diagram, vehicle (24 V, pos. 1-8)

F
M
A
-

-
C(')nnector, chassislcab
Connector, engina
Connec tor, cab
[2] Headlights
b 1 Combination swi tch
0 , Transm iSSion " Double H gearshitt pattern"
b13 Switch speed range
VG _ Connector, transformor behind cab b38 Test connec tion starting lock 2 Relay Indicator lights
VD .. Connector, junction bo)!., rear
h ,
e I-a 4 Fuses
High beam indicator light
3 Headlight, lell
d
e 7
3

h 11
Relay
Fuse
Indicator light speed range
Wire color code "
h 4 Headlight, right
h 4'
R, C. 1st to 4th gear
Indicator light speed range

b, -
.,,. --
b' blue
brown
12] Fog lights
, 5
5th to 8th gear
Series resistor

--
ivory
yellow b 4 Push button switch
go green
,
b 5 Plug socket
[2]
"-
1 Relay Turn signal lights
grey
h 5 Indicetor light In switch b 4
U
-
" - <0'
",w
violet
pink
b
b
1 Combination switch
8 Tra iler plug sockat 24 V
b15 Hazard warning flasher switch

"'
black
white ~ Brake system, backup light
b 6 Stop light Switch
b16
e 8
Trailer plug sockot 1211
Fuse
h 12 Indicator light in switch b 15
1 switch L-H drive h 13 Turn signal Indicator light, trac tor
Example b 7 Stop light switch h 14 Tu rn Signal light, right, on side
3 switches, A-H drive h 15 Tu rn si gnal light, right, Iron t
Wire designation t .5 grlrt b 8 Trailer plug socket 24 V h 16 Turn signal light, righ t, rea r
Cross section of wire 1.5 _ 1.5 mm z b 9 Switch, backup light Turn s:gnallighl, loll, on side
Basic color gr - grey b 10 Switch, exhaust brake " 17 Turn signal light, loll, fron t
Indenlification color rt _ red b 11 Switch for solenoid valve s 1 " 18 Turn signal light. left. rear
"19
e 5 Fuse "'0 Turn signal indicator light, trallor
6

""" 7
8
Stop light, left
Stop light, right
Warning 1lghl - hydraulic brake ,
,
1 Series resistor (Iocallng light)
Series resistor, turn signal light
Series resistor, turn signal light
3
control 3 Turn signal sending unit
," 91 Backup light "
Solenoid va lve, brake pressure.
front axle
[2] Po wer supply, starter control
El Windshleld wiper system
a
b
d
2
2
8
Switch bv)!.
Starter pushbutton
Relay starter
0 Horn, 2nd slarter pU$hbutton
b 1 Combination swilch
b 1 Combination Switch
a = on
b '" o ff
h 1 Charge indicator light b 3 Switch starting lock b17 Foo t-operat ed switch
m 1 Starter b 12 2nd starter pushbutton on engine e 9 Fuse
m 2 Alternator e 6 Fuse m 3 Windshield wiper motor
n t Batteries Horn 4 Wiper pulse generator
" 10 "

138
 1 - - -"- - - - "

,, ., " I~ 1&
L
-DJ-
Key to wiring diagram, vehicle (24 V, pos. 9 to 21)

0 Heater
b18 Switch. h eater blower motor
h 31
h32
Indicator light. Inter-axle
differential lock. fron t
Indicator tight, inter' 8JO:le
G Interior lights, tachograph
b32 Switch, interior light
.10 Fuse differential lock. rear b 33 Switch, interio r light
m , Heater blower motor h33 Indicator light. brake fluid b34 Switch, Interior light
b3S Door contact switch
.17 Fuse
13 Operation monitoring equipment 9 3
h43
Tachograph
Instrument lighting
b19 Switch. 3rd brake circu it
b 20 Switch. buzzer, cooling water
temperature
G Exte rior mirror heater
b14 Push button switch with indicator
h44
h4S
Interior light
Interior ti ght
b 21 Switch, differential lock. front axle light h46 Interior light
b 22 S .... itch. differential lock, ,
• 122 Fuse
1$t rear axle
b 23 Switch, diflerent iallock.
, Exterior mirror heater, lell
3 ElCIerior mirror heater. right G RadIo
.18 Fusa
2nd rear axle 1 Radio
p
b 2' Control switch, PTO I and 11
b 2S
b26
Control switch, dump body
Control switch, hand brake @] Pa rking light, left; clearance lights
@) Hazard warning flasher system
b 27 Switch inter-axle differential
lock. l ront
b
d •
S
Trailer plug socket 24 V
Relay .19 Fuse

".
b29
Switch, Inter-axle differential
lock. rear
Sending unit for brake Uuid
•h34
13
h3S
Fuse
Parking light, left
Tail light, left G Plug socket

030
d ,
11
Control Switch brake pad wear
Relay
Fuse
h36
h37
h38
Clearence light. left
Clearance light, right
Marker light. left
b36 Plug socket
.20 Fuse

2 Sending unit for oil pressure

gauge
h39 Marker ligh t, right
G d
Fog lights
1 Relay
3 Sending un it for coolant .21 Fuse
I , temperature gauge
Sending unit for fuel gauge @] Parking I1ght, right h47 Fog light, right
h48 Fog tight. left
9
9
h21
1
2
Instrument cluster
Tachometer
Instrument righting , instrument
b
d •
6
Trailer plug socket 24 V
Relais
Fuse
~ Electronic ch arging balance
cluster •h40
14 Parking light. right e 22 Fuse
h22 Brake pressure warning light
h41 Tail light, right r 4 Series resistor
h23 Buzzer, monitoring cooling water
u 6 Electronic charging system
temperature end engine speed
h24 Instrument lighting, tachometer
h2S Indica!or light. differential lock, @] Ta il light, left, right; exhaust brake

h26
front axle
Indicator light. differenUallock,
1st rear axle
G Instrument panelUghtlng
031 Dimmer switch, lnstrumel'lt panel
b
b
16
37
Trailer plug socket 12 v
Switch, exhaust brake
h27 Indicator light, differential lock. lighting d 5 Relay, tail light. left
2nd rear axle Fuse d 6 Relay. teil light, right
h28 Indicator light. PTO I and 11 • IS
.16 Fuse d 7 Relay
h29 Indicator light, dump body h42 lighting for heater and ventilation e 23 Fuse
h 30 Indicator light, hand brake control .e 24 Fuse

140
 mell
'1' ..
rI -'·

'"
L
111 128
-@!-
". 150 15 1 ,e. .

141
Key to wiring diagram of steering lock 30 30

Steering loc k t
1
d1 Relay ,I
Isw/bl -ge
d2 Relay D.
1 ~
n1 Diode t1 Ff6/5 Fr 6/1
F Connector
Standard equipment
bl ,s
,w
4
,I

~
86 870 87a
d2 n1 )
85 30 -r sof"i>" 4 I.S l ,S
,I
1,5 sw sw
br ge 1
~
I ,.
F6/6 F6/3t F614
I,w
fl_
y
1
lsw/bl-ws
86 30
dl
1
as
8'L
I
1
b,
2,5sw-1

142
Key to wiring di agram
seat heater

2
Seat heater switch
Plug connections - swi tch
~
mr y 4 5
~"5,ug.---F.>t-,~gn/g.-F.'1--'SW1i':l
I-~~!'
3 Fuse (fuse box Ill)
4 Plug connection - body waist /' / /' / s/ I
5 Plug connection - seat
6 Heating pad, back rest
7 Heating pad, seat
oH I.' r-"b'/SW[ni',5b'---ri 'b' ._J
n I :::t'--1,5li/gn----tmt-I,SW-tmt-'SW----,
. n II II
l
/ I / I I
I
i
1b,,5 [',b'Td-
IV .
i I
i I
i IV '
L .J
lb
,5b,- - cd - - '

1 ••

143
7 Tig hteni ng torques - summa ry in Nm (lb-It)

En gi ne Front axle
Cylinder head cove r. 25(18.1) Front sprin g U-bolt. 280 (202.5)
Cylinder head bo lts. .... .. . . 110 (79.6) Front ax le cover(pal loid axle) . 50 (36 .2)
Rocker arm bracket 100- 11 0 (72-79.6) Oil filler and drain plug . . 80-100 (57.8- 72.3)'
Oil pan M6 . . . . . . .. . . 8 (5.8)
M8 ... ......... ...... . 9 (6.5) Rear axle
Oil drain plug -oi l pan . . 80 + 10 (57.8 + 7.2)
Oil filter bowl to oil filter top . 40 + 10 (28.9 + 7.2) Air spring bracket, rear 750 (542.5)
Oil drain plug to oi l filter bowl Rear spring U-bolt M 18 x 1.5 280 (202 .5)
Engine3S2 ... 15 ± 2 (10.8 ± 1.4) M20x 1.5 400 (289.3)
Rear axle cover. 50 (36.2)
Engine 352 A . 50 + 10 (36.2 + 7.2)
Engine support arm to engine 160 (115.7) D ifferent ial
Engi ne support arm to crankase 170 (123.0) Oil filler and drain pl\JQ .. 80 -1 00 (57.8-72.3)
Eng ine support arm to clutch Planetary hub reduction gear
Oil filler plug . 160-180 (115.7-130.2)
housing . 180 (1 30.2)
Oil drain plug .. . ......... 80-100 (57.8-72.3)
Hoseclamp. 6 (4. 3)

10 -7 '2 . - ,,
p"
.-J..:.;:-
-7 j·S
1:54, -
:5~ 7· 5

144
Wheels Steering
Disc wheels: Pitm an arm mounting L 5Z 750 (506.3)
Centering via spherical spring LS5 F 750 (506.3)
washers and whee l studs LS7F . 750 (506.3)
Wheel nuts M 22 x 1.5 450 (325 .5) Clamping sleeve to tie rod . 60 -70 (43 .3- 50.6)
Centering by means of wheel hub Conical jOints - tie rod
Wheel nuts with pressure disc M 16 x1. 5 . 120-140 (86.8-101.3)
M 22 x 1.5 600 (434) M 18 x 1.5 ....... . 160-190 (115.7 - 137.4)
Tril!ex wheels: M 20 x 1.5 . . ....... . ... . 220-250 (159.1-1 80.8)
T ri lex ri m to wheel spider Oil filler and drain plug . ... . . .. . . 50- 55 (36 .2- 39.7)
Nuts of brazier head screws
M 18 x 2 300 (217)
M 20 x 2 350 (253.2) Brake system
Wheel adapter ring to hub Spring brake release bolt . 40 - 50 (28.9- 36.2)
Centering via spherical spring
washers
450 (325. 5) Trailer coupling
Whee l nuts M 22 x 1.5
Centering by means of wheel hu b Coup li ng rod cap nut . ....... . 350-800 (253.2-578.6)
Wheel nuts with pressure disc
M22 x 1.5 ........ . 600 (434)

.~ -

145
 8 Capacities - summary -Components and lubricants must match. Therefore, on ly tested and reco mme nde d
brands must be used. M ERCEOES-BENZ service stations will give you all the informa-
tion.

Model ICapacities approx. Fuel, coolant, lub ri cant

o r brake Iluid

ma x. 16.5 I
(34.9129.1 US.'Imp. pI)
352 353.94.
min. 11.5 1
(24 .3120.4 US/Imp. pI)
Engine with oil filter
max. 17.5 I
(37.0130.8 US/Imp. pI) SAE grades
352 A 353.95, Engine oil
min. 12.51 see section 3 .2
(26.4/22 US/Imp. pt)

Engine 352 - 1,7 I (3.6,'3.0 US/Imp. p I)

Oil bath air filter
Engine 352 A - 3 I (6.315. 1 US/Imp. pi)

G 3150 Automatic transmission

G 3/60
714,0 .. 5 I (10.518.8 US/Imp. pi)
fluid (ATF), Type A, Suffix A -
Transmission
G 3165, G 3/90 714.2 "' 714.3. 10.5 I (22.0/16.4 US/Imp. pI) Transmission oil SAE 80, 80 W, 80W,35 Wl
NA 3/60-1 - + 0.3 I (0.610.5 US/lmp. pI) Automatic transmission
fluid (ATF), Type A. Suffix A -
NA 3/60-10/11 - + 1.51 (3.2;2.7 US/Imp. pI)
+ Power take-off
NA 3/90-2 - + 0.5 I (1.1109 USllmp. pt)
SAE 80, 80 W, 80 W/85 Wl
NA 3190-10/11 - + 2.8 I (5.9/4 .9 US/lmp. pt)
Transmission oil
VG 500-3 W 750.5 .. 5.51 (11.7/9.7 US/Imp. pt)
Transfer case SAE 80, 80 W, 80 W/85 W'
VG 850-3 W 750.4 .. 4 I (8.517. 4 US/Imp. pt)
HL 4t8, HL 4116, 74 4.5 ., 744.3.. , 5.21 (11.019.2 Us'·l mp. pi)
HL 4t17 744.4 ..
Hypoid gear oil SAE 90, 85 W/90
Differential HL 4."01 745.6 .. 11 I (23.2f9.4 US Imp. pt)
Rear axle
HL 7/1 740.1 .. 7.5 1 (15.9113.2 USll mp. pI)
Transmission oil SAE 80, aD W, 80 WI85 W1
Planetary hub 2.75 I each
reduction gear HL 7/1 - (5 .814.9 USllmp. pi)

1 SAE 90, 85 W: 90 oil may be used at ambient temperatures continuously above + 86" F (+ 30' C).

146
 Model I Capacities approx. Fuel, coolant, lubricant
or brake fluid

AL 316 731.6 .. 6.21 (1 3.1/ 10,9 US/Imp, pt)

Live front axle
AL 317 731.3 .. 5 I (10.618.8 US/Imp. pt) Hypoid gear oil SAE 90, 85 W{90
Manual steering LSZ 760.4.. 1.5 I (3.2/2.7 US/Imp. pt)

lS5 F 765.2 .. 2.8 I (5.9.' 1.9 USIlmp. pt)

Power sleering
LS 7 F 765.3 .. 3.8 I (8.0; 6.6 US.lmp. pt)
Automatic transm ission
fluid (ATF), Type A SUm)!; A -
Brake sytem-hydraulic section - 1.0 I (2.111.7 USIImp. pt)
Brake flu id -
Hydraulic clutch and brake conlrol system - 0.7 I (1.511.2 USIImp. pt)

Cab tilting system - 0.6 I (1 .211 ,0 USIlmp. pt)

Hydraulic dumping s{stem
oils or hydraulic oils -
Sliding sleeve on clutch release bearing - Lon g-term g rease -
Tilting cab mounting -
Fronl wheel hub VL 2 730.8 100 g each (3,5 oz)

Front whee l hub VL 3 730.0.. 150 g each (5.3 oz)

Front whee l hub Al 3 731.6 .,731.3 " 600 g each (21 .2 oz) Multipurpose grease -
Rear wheel hub HL 4 744.5 ., 744.3 "
200 9 each (7 oz)
745.6"
Grease nipples on chassis and body -
Batlery terminals - Bosch Ft 40 v 1 -
105 t (27.7 (23.1 US/Imp. gal)
1351 (35.7. 29.7 US/Imp, gal)
2 x 135 I (35.7129.7 US/Imp. gal)
Fuel tank - 200 I (52.8.44.0 US/Imp. gal)
Diesel fuel -
2 x 200 I (52.8144 .0 US/Imp. gal)
or 300 I (79.2166 US/Imp, gal)

Cooling system - 261 (54.9/45.7 US/Imp. p i) to

32 I (67 ,6156 .4 US/Imp. pt)
Coolant -
Windshield was her - 4 I (8.416.8 US/Imp. p t) Wate r wilh MB-windshield
-
washing agent
Headlight washer system - 3 I (6.315.2 US/Imp. pt)

1 Auto matic transmission fluid (ATF) Type A Suffix A can be used.

147
 .'
011 change on unIts
9 Service and maintenance jobs - summary
(For detail s refer to ma intenance book let)
Maintenance
category I
Mil lo!e"ance
category 11
Mainte nance
category III
"~ " ! ii ·
:
--~
- :=1
NaturallYI~j
'I'
J aspirated
engine IL
TUrbo-
, charged
----l engine
r·';"'1
--,' ~~
( I

r~ 1l~
1111
Up to 10000 km Up to 100000 km Above 100000 km Engine oil Engin e 011
(6000 miles) a year (60000 miles) a ye ar (60000 miles) a year
Servere operating Super
conditions HO 53 53 53
0 0
Inspection
alter 500-1500 km
(JOO 900 miles)
alter 500-1500 km
(300 -900 miles)
alter 500-1500 km
(300-900 miles) 'I' 'I'
• • • •
Oper- Mileage Oper- Mileage Oper- Mileage
a ting aling ating
hours hours hours
(h) (km) (miles) (h) (km) (miles) (h) (km) (mil es)

Service 100 5000 (3000) 200 10000 (6000) 300 15000 (9000) 'I'
•
MaIntenance 200 10000 (SODO) 400 20000 (12000) 600 30000 (18000 ) 'I' 'I'
• • • €I
Service 300 15000 (9000) 600 30000 (18000) 900 45 000 (27000) 'I'
•
Maintenanc e 400 20000 (12000) 800 40000 (24000) 1200 60000 (36000) 'I' 'I'
• • • • •
Service 500 25000 (lS000) 1000 50000 (30000) 1500 75000 (45000) 'I'
•
Maintenance 600 30000 (180 00 ) 1200 60000 (360 00) 1800 900110 (54000) 'I' 'I'
• • • €I
Service 700 35000 (21000) 1400 70000 (42000) 2100 105000 (63000) 'I'
•
Mai ntenance 800 40000 (24000) 1600 80000 (48000) 2400 120000 (72000) 'I' 'I'
• • • • •
Service 900 45000 (27000) 1800 90000 {54 000) 2700 135000 (B1000) 'I'
•
Ma intenance 1000 50000 (30000) 2000 100000 (60000) 3000 150000 (90000) 'I' 'I'
• • • €I
Service 1100 55 000 (33000) 2200 110000 (66000) 3300 165000 (99000) 'I'
•
Mainten ance

etc.
1200 60000 (36000) 2400 120000 (72000) 3600 180000 (108000) 'I' 'I'
• • • • • •
0 Change 11nl:;"e o il and tilter It IN sI twice I yt'llr.
but . 1 least once a yea r if SAE 15 W-.O 011 is used .
OB Sp(le, liea l'Ons for service produetl:
HO angina oil slleet 226_0
€I Hol Ipplicable 10 veh icle equ ipped
wilh plane t.lry ule5
S 3 engine o il sheets 22.7 .Dl227 .1
Super S 3 engine oil sheel 228.1

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