Electric
Electric
Electric
Product overview
The Mercedes-Benz Truck division has changed continually over the years. Not just in terms of
the appearance of the vehicles or the engines used, but also in terms of their electrical compo-
nents and networking. The following is an overview of current Mercedes-Benz Truck products.
The Antos model series is discontinued following the launch of the Actros 5. The Actros 5
adopts its previous vehicle and cab variants.
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The 220 Ah battery is mainly installed in the long-haul Actros truck (model series 963). Drivers
"live" in these vehicles, which means that the batteries are subjected to the greatest stresses
and are often heavily discharged.
The lead battery does not make use of pure lead but an alloy (PbSb) consisting of lead (Pb) with
some antimony (Sb). This makes the material harder. However, the disadvantage of antimony is
that these batteries consume a certain amount of water and self-discharge to some extent.
These two characteristics mean that these batteries cannot be designated "maintenance-free".
However, there are also batteries which use a lead-calcium alloy (PbCa). The water consump-
tion and self-discharge tendencies of these batteries are much lower. This means that they are
suitable as maintenance-free batteries. The disadvantage, however, is that they are seriously
damaged after deep discharging and then often have to be replaced.
The current truck model series have hybrid batteries (wet batteries) installed as standard.
In this case, the negative plate's alloy contains calcium while the positive plate is alloyed
with antimony. These batteries are designated "maintenance-free".
The "AGM Truck Test" app is available for this purpose. A detailed user guide and instruc-
tions can be found in XENTRY TIPS under GI54.10-N-069274
Additional information about possible retrofitting of the AGM battery can be found under
SI54.10-W-0066A
Arrangement of batteries and B-junction box in Actros (model series 963) and Arocs
(model series 964)
Integral rear area - code C7T Batteries adjacent to one another - Batteries stacked above one an-
code C7J other - code C7K
B-junction box
The B-junction box contains the battery sensor connection The terminal 31 current tap for retrofitted equipment with
to the negative line (charger connection). high power requirements is carried out via the 8 mm stud
in the B-junction box
The only battery installation location on the Atego (model series 967) is on the left side. There
is no battery sensor and thus also no B-junction box.
Battery sensor, shown on vehicle with code C7T (integral rear area)
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G1 Battery
Design
The battery sensor contains an electronic control unit for measured data acquisition and pro-
cessing (microcontroller), and a precision resistor.
Function
The battery sensor calculates the batteries' charge state and starting capability by measuring
the battery voltage at the battery terminals, the battery temperature at the battery ground ter-
minals, and the current via the voltage drop at the precision resistor.
The battery sensor sends the result of the calculation on request via ASAM-LIN 2) to the Advanced
Sensor and Actuator Module (ASAM) control unit (A7).
Component description
Nut M6
1 Terminal 7
Tightening torque 7 +/- 1 Nm
2 Housing 8 Terminal screw M6
The intelligent battery sensor is attached to the negative terminal of the lower starter battery
and consists of mechanical components, an electronic unit, and the corresponding software.
The mechanical components consist of the battery terminal connection with the ground cable
on the battery. This is done using the terminal screw (8) and the accompanying nut (7).
The electronic unit comprises a printed circuit board with the electronic analysis system and a
microprocessor. There is also a shunt precision resistor and an NTC temperature sensor. The
electrical connection has three pins.
Pin 1 = 12 V
Pin 2 = LIN bus connection
Pin 3 = 24 V
Function
The intelligent battery sensor (IBS) records:
The battery temperature
The battery terminal voltage
The battery current, charging current and discharge current.
The 68 µΩ shunt precision resistor causes a voltage drop, which allows calculation of the start-
er battery's current and voltage. Pin 3 (24 V) supplies the sensor with voltage. The temperature
is recorded at the terminal clamp by an NTC resistor and analyzed by the electronic unit. The
battery sensor transmits the collected data to the ASAM control unit via pin 2 (LIN bus). The
ASAM control unit evaluates this data and automatically initiates the extended consumer
shutoff function if the battery status is low. The ICUC (Classic Cockpit) or ICS (Multimedia
Cockpit) instrument cluster informs the driver that the consumer shutoff function is active and
prompts the driver to start the engine.
Retrofitting
The M8 hexagon head bolt (11) should be tightened to max. 14 Nm and is intended for retrofits
by body manufacturers ('bodybuilders').
The body/equipment mounting directives must be consulted and observed for every retrofit!
You will find this information in Book II, Chapter 7, Electrical system.
It is available on the following website:
https://bb-portal.mercedes-benz.com
Battery replacement
If the battery type, ASAM or battery sensor are changed, the corresponding battery parameters
must be adapted. Go to ASAM and ADAPTATIONS to call up the corresponding menu item and
perform parameterization. The battery sensor can be found under INITIAL STARTUP, while the
battery, battery disconnect switch and consumer shutoff are under PARAMETERIZATION.
As soon as a battery is replaced and the same battery type is reinstalled, the battery sensor
must be notified of this by means of a reset command. The data compiled about the removed
battery are then erased.
When screwing the vehicle ground line to the outer M10 battery pin (10), the connection should
be tightened to the appropriate torque of max. 17 Nm. Otherwise torque may be applied to the
shunt/pin plate solder connection (5).
The alternator is mounted on the side of the engine and is powered by a belt drive. The alterna-
tor is designed to induce a voltage when the engine is running, which supplies both the on-
board electrical system and the batteries. As the engine rpm increases, the induced voltage al-
so increases, and vice versa.
1 Alternator
The alternators are designed as compact alternators with different output ratings. The following
alternators are used in the Actros (model series 963) and Arocs (model series 964).
E1N - 28 V/100 A alternator with 2800 W
E1M - 28 V/150 A alternator with 4200 W
E1T - 24 – 30 V/100 A LIN alternator with 2800 W
E1U - 24 – 30 V/150 A LIN alternator with 4200 W
Only the following alternator is installed in the Atego (model series 967):
E1N - 28 V/100 A alternator with 2800 W
The (LIN = Local Interconnect Network) alternator has intelligent control, which recuperates
current and relays it to the truck's electrical system (battery/on-board electrical system).
The intelligent control enables the alternator to charge the battery with maximum power
(U > 28.3 V) during engine braking. When the engine braking torque decreases
(U < 28.3 V), the recuperated energy is relayed to the on-board electrical system. It is
therefore also called a "regulated alternator".
Versions
The consumers installed in the Actros 5 are protected by two power distributors (PDM).
PDM arrangement
W54.10-A003-79-color
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Truck_000084
The Chassis PDM supplies consumers outside the cab with protected battery voltage. There are
changes to the component compared with the Actros 4 power distributor. The CLCS, EAPU,
ASA, and components of the EPAC are supplied with protected battery voltage via the addition-
al connector (X15.8). These consumers are protected by means of ATO plug-in fuses (F1/A152
to F8/A152).
Consumers with higher power consumption are plugged into connections X2 - X13. They are pro-
tected by safety fuses held in place by screws. Power is supplied from the battery to the PDM via
the connections X1 or X14, depending on the vehicle variant.
Function
The relays arranged on the Cab PDM are activated by the ASAM (A8). The voltage supply to the
relay input is internally connected. The consumers supplied by the relay are protected after the
particular relay output. A relay output supplies the connected consumers with protected volt-
age via several safety fuses.
Relay arrangement K1 - K8
K1 Control terminal 15/1
K2 Supply D+ consumer
K3 Trailer brake lamp
K4 Bistable relay second stage consumer shutoff
K5 Air conditioning supply, door modules and radio
Terminal 15/1
Terminal 15 A8 - K1 1/2
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Terminal 15 A8 - K1 2/2
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Terminal D+
Terminal D+ A8 - K2
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Terminal 54
Consumer shutoff
Consumer shutoff A8 - K4
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Terminal 15 - ACC
Terminal 15 A8 - K5 "ACC"
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Terminal 15/2
Terminal 15 A8 - K7
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Consumer shutoff
Consumer shutoff A8 - K8
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If there are retrofits on the power distributor or on the vehicle, the appropriate wire cross-
sections, seals and fuses must be used. The wires must be routed safely. They are not
allowed to chafe and must be securely fastened.
CAUTION
Due to the ground return, all of the connections described before can take a total of maximum
200 A long-term (maximum 250 A if limited to 60 s). The relevant provisions in the
Body/Equipment Mounting Directives must be observed.
Cab PDM
W54.10-A005-78-color
A8 Cab PDM
The current consumption of all consumers subsequently connected at connector X15 may
not exceed 10 A.