Global Service & Parts

Mercedes PowerShift brochure

Experiences and tips from driving experience for the service area

Mercedes PowerShift has been used in the Actros since December 2006 and in the Axor since
September 2007. With the Actros 3, the second generation of this automated gearshift was
introduced. The following pages are intended to offer a bundled series of helpful suggestions that
have resulted from the previous driving and workshop experience.

The presented information may help protect the customer and his/her employees from incorrect
operation and optimally use the Mercedes PowerShift from the very beginning.

Mercedes PowerShift variants:

Code overview:

Transmission variants
Code Main variants Code
(Depending on the main variants)

GE3 Mercedes PowerShift GH2 Mercedes PowerShift G 211-12/14.93-1.0

GE7 Mercedes PowerShift 2 GH3 Mercedes PowerShift G 281-12/14.93-1.0

GE8 Mercedes PowerShift 2 - fleet series GH4 Mercedes PowerShift G 280-16/11.7-0.69

G86 Double-plate clutch GH7 Mercedes PowerShift G 241-16/17.1-1.0

GK8 Turbo clutch GH8 Mercedes PowerShift G 330-12/11.63-0.77

Modification overview:
Major differences/new features (software and hardware) of the PowerShift 2 (GE7) systems
compared to the PowerShift 1 (GE3):
Shifting strategy/shifting comfort:
- The shifting strategy was adapted with the use of PowerShift 2 for the benefit of the fuel
consumption. This expresses itself above all through situation-specific
lower subsequent rpms and higher gear steps.
- You can leave maneuvering mode via kickdown (a brief acoustic warning sounds).
- Constant throttle can be incorporated during the shift operation (above all high gear
steps) for faster rpm synchronization.

Display:
- EcoRoll mode is shown with "E" instead of "N" in the display.
- No more pop-ups in the instrument cluster if automatic gear selection modes switch (Eco
Power - etc.).

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Starting off:
- Table for start-off gear optimized. 22 t corresponds to start-off gear 3 on the flat.
- Automatic start-off logic with difficulties starting off (e.g. loose surface) in gears 1 and R1
(rpm increase with ramp to max. 1100 rpm (see TIPS info)).

Sensing:
- New main shaft rotary sensor, omission of B57 (direction of rotation rotary sensor),
inclination sensor introduced in transmission control unit.

The transmission (GS) control unit and drive control (FR/CPC) control unit are not
exchangeable with one another in the respective shifting systems.

Possible clutch variants depending on the transmission variants:

Single-plate clutch Double-plate clutch Single-plate clutch

(long bearing) (short bearing) (short bearing)

Mercedes PowerShift G 211-12/14.93-1.0 x

Mercedes PowerShift G 281-12/14.93-1.0 x x

Mercedes PowerShift G 280-16/11.7-0.69 x x

Mercedes PowerShift G 241-16/17.1-1.0 x x

Mercedes PowerShift G 330-12/11.63-0.77 x x

Tips for service:

With the G211 transmission, no double-plate clutch can be installed due to the insufficient
installation space.

Following successful conversion of the clutch variant (single-plate or double-plate clutch), the
corresponding value in the "Parameter group for Mercedes PowerShift 2" must be adjusted in the
FR/CPC control unit. (only affects Mercedes PowerShift 2).

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The concept of Mercedes PowerShift

Overview:
The second generation of Mercedes PowerShift (GE7) works exclusively with 12 gears. For special
applications, the 16-speed variant from the first generation (GE3) is available.

Mercedes PowerShift does not only take on the automatic gear change and the actuation of the
clutch, but also offers various additional functions - from EcoRoll mode and the rocking and
maneuvering mode to direct shifting from 1 to R. These additional functions require that the driver
activate a corresponding button, for example.

In combination with the Mercedes PowerShift 2 (GE7) 12-speed transmission, the "fleet series"
variant (GE8) is also available, meaning the same automated shift mechanism but with limited
additional functions. Its operation is simplified to such an extent that the switch for changing to
manual mode is omitted and the kickdown function of the accelerator pedal is deactivated. The
operating procedures that lead to an increase of the fuel consumption are thus excluded. For
additional information on retrofitting or backfitting code GE8, please refer to SI30.35-W-0003A.

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Economy preprogrammed

The shifting philosophy:

The shifting philosophy from Mercedes PowerShift is arranged such that in automatic mode in all
driving situations, the best possible gear is engaged with regard to the fuel consumption.

Before starting:
Upon switching on the ignition, the system initially assumes a maximum load with 40 t gross
weight and selects - depending on the 12 or 16-speed transmission installed - the correct start-off
gear for this. Following about five shift operations, the transmission control has determined the
current load and driving situation using various parameters and the incline angle sensor (only with
Mercedes PowerShift 2 12-speed transmissions).

Tips from practical work:

If loading and unloading is performed with the engine running, the start-off gear is still calculated
in accordance with the previous load condition. We therefore recommend switching off the ignition
where possible during a load change and restarting, or as an alternative manually changing the
start-off gear.

Starting off during the drive:

Mercedes PowerShift recognizes the load condition from the preceding driving situation with
acceleration and deceleration. Mercedes PowerShift 2, in combination with the incline angle
sensor, can thus even select the best fitting start-off gear on inclines.

Tips for service:

The incline angle sensor does not need to be set or calibrated. The function of the sensor can be
checked by adjusting the level control. Please note that the value on the flat may differ slightly
from the value "0". The value of the current vehicle incline can be shown in the GS control unit as a
raw value in the unit "g" and in the FR/CPC control unit as an extended actual value in "%".

When driving:
The gear selection and the automatic change of gear ranges are always oriented toward the
respective driving situation. The vehicle gross weight, the inclines and naturally the request from
the driver via the gas pedal are thus taken into account when selecting the correct gear range.

When driving on inclines and with decreasing speed, the vehicle shifts back to the gear that
guarantees the vehicle the best possible continued journey following the shift operation based on
the load and incline recognition.
When upshifting on the flat, shifting steps of up to three gears are possible. When driving on
inclines, the maximum gear steps are smaller. The shift point and thus above all the shift rpm
varies depending on the topography and load requests.

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Tips from practical work/for service:

Shifting behavior on inclines:
On inclines, gear steps of up to 2 gears are possible. Due to greater requirements placed on the
engine power, the shift rpms are increased depending on the determined incline, among other
things.

Shifting behavior in deceleration mode:

With the vehicle rolling, an automatic downshift is performed at approx. 800 rpm.

Shifting behavior with an activated brake application:

By activating a wear-free brake, the downshift rpms are raised.
With an actuated service brake, no downshift is performed below 25 km/h. We therefore
recommend, e.g. when braking upon approaching a rotary or an intersection, engaging the gear
appropriate for the driving situation. This can be performed as follows:
- Briefly release service brake
- Poss. briefly apply gas (in good time before obstacle)
- Manual intervention at shift control unit

Manual intervention in A mode:

If the driver performs a manual gear selection with A mode active, the engaged gear remains
engaged for approx. 30 seconds. This function remains active even though the automatic gear
selection (AG) would select a different gear for the current driving situation.

Shifting behavior with activated lock:

With switched on interaxle differential lock, the shift and target rpms are increased to ensure more
dynamic driving behavior. Driving with a switched on interaxle differential lock increases the fuel
consumption due to the higher rpms. The lock should therefore only be used in the driving
situations required for this.

In the event of stopovers:

Following the stopping procedure, the clutch initially remains open and the gear engaged. To
protect the clutch operating mechanism, a warning tone sounds and the gear indicator flashes in
the Actros after 60 seconds (90 seconds in the Axor). After an additional 30 seconds, the neutral
position "N" is then automatically engaged.

Tips from practical work:

With foreseeably longer stops, you should quickly shift into the neutral position manually after
stopping in order to protect the clutch operating mechanism.

When parking the vehicle:

Upon switching off the ignition, the transmission is automatically shifted to neutral position. This
ensures that a restart (e.g. in the event of pressure loss) is possible without problems.

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Tips for service:

With Mercedes PowerShift 2 (code GE7), a cyclical noise from the clutch actuator can be heard
with ignition on (tml. 15 on). This is a zero point comparison that is performed by actuating the
solenoid valves.

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The additional functions

The automated engaging of the clutch and shifting of the Mercedes

PowerShift relieves the driver. Additional functions
make it possible to individually deal with even challenging
driving situations. The maneuvering mode and the
rocking mode, for example, thus provide efficient support
for the driver.

The maneuvering mode:

The maneuvering mode supports a finely modulated and slow maneuvering of the vehicle in the
gears 1 and R1. This is valid when approaching a ramp or when coupling and uncoupling. In
maneuvering mode, the entire accelerator pedal travel is available for fine modulation of the
clutch. The maximum rpm is limited to 1000 revolutions.

It is possible to exit the maneuvering mode as follows:

- Mercedes PowerShift 1 via the modular switch in the modular switch panel
- Mercedes PowerShift 2 via the modular switch in the modular switch panel or the kickdown
switch

Tips from practical work:

To reduce wear of the clutch and the clutch operating mechanism, the maneuvering mode should
be used only for a limited time, e.g. for the last 1 to 2 meters for driving onto the ramp. Activation
is only possible in the first reverse and forward gear.

The rocking mode:

The rocking mode is only available in the first forward and reverse gear. Opening and closing of the
clutch is accelerated considerably. The rocking mode thus allows a vehicle that is stuck to begin
an oscillating movement.

The power mode:

The power mode offers a shifting strategy designed with higher rpms. Compared to standard
mode, all shift operations are performed with an approx. 100 rpm higher rotational speed. In
power mode, only the rpm is increased, the output only increases marginally.

In on-road vehicles, the power mode is automatically deactivated after 10 minutes. In off-road
vehicles (Actros construction), the power mode is not automatically deactivated and remains

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permanently active. With activated power mode, the EcoRoll mode is in turn deactivated.
Retrofitting of the Actros construction function in on-road vehicles is not possible.

Tips from practical work:

Driving in power mode increases the fuel consumption due to the higher rpms. You should
therefore only use power mode in a targeted manner if higher rpms and shift points are truly
necessary.

The EcoRoll mode:

The EcoRoll mode optimizes the existing energy in deceleration mode by decoupling the engine in
a targeted manner. If no load request exists in deceleration mode via the gas pedal and brakes,
Mercedes PowerShift shifts into neutral position in a controlled manner. As soon as the driver
again accelerates or brakes, whether with the wear-free brakes or with the service brake,
Mercedes PowerShift immediately shifts back into the required gear range. The EcoRoll mode can
be deactivated and reactivated if necessary. After switching on the ignition, the EcoRoll mode is
generally activated.

The EcoRoll mode is only active when the ground speed is higher than 55 km/h (or at least gear 7
as well with Mercedes PowerShift 1) and the hysteresis is at least +4 km/h. In the display with
active EcoRoll mode, and "E" is shown for the engaged neutral position (or "N" with Mercedes
PowerShift 1).

Tips from practical work:

Use of the EcoRoll mode may increase the shifting frequency in certain driving situations. For this
reason, the EcoRoll mode is to be deactivated where applicable in slow-moving traffic and at
speeds greater than 55 km/h as well as on demanding topography (uphill – downhill), for example.

The kickdown:
Irrespective of the load request, below 1500 rpm the kickdown enables a brief increase of the shift
rpm, e.g. before or on inclines. With permanent actuation of the kickdown, all shift rpms increase
by approx. 200 rpm compared to the standard mode.

Tips from practical work:

The kickdown should only be used for a brief downshift operation. Following the downshift
operation, you should continue driving without kickdown. Activation of the kickdown function
considerably increases the fuel consumption.

Note:
Upon activating kickdown, the maneuvering mode is deactivated if this was previously active (only
with Mercedes PowerShift 2).

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The direct shifting from 1 to R:

By pressing the skip-shift button, a rapid shift from 1 to R and R to 1 is possible without having to
shift into neutral position first.

Tips from practical work:

You should only use the direct shifting if a rapid change to the direction of travel is required, e.g.
when maneuvering.

The reverse gears:

In Mercedes PowerShift transmissions, four reverse gears are available. After engaging the 1st or
2nd reverse gear, additional reverse gears can only be engaged using the shift paddle. This is only
possible, however, at the corresponding reversing speed and corresponding high shift rpms
(approx. 1800 rpm).

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The displays in the multifunction display

Easy to detect:
The driver is constantly informed of the
operating condition of his/her vehicle
and the engaged additional functions.
Mercedes PowerShift shows the current
operating condition in the multifunction
display.

Multifunktionsdisplay mit Anzeige von Betriebsmodus (1),

aktuellem Gang (2), Getriebe-Neutralstellung des EcoRoll-
Modus (3) und Automatikbetrieb (4)

Prompt 16-speed Transmission Prompt 12-speed Transmission

Display of the gear range:

With the 16-speed transmission, the gear ranges are shown with splitter group arrows. With the
12-speed version, on the other hand, only whole gear ranges are shown. The following table
describes the assignment of the gear indicator to the actual gear engaged together with the
splitter and range.

Display in the INS Actual Gear shifted

1 1. Gear Low
2 1. Gear High
3 2. Gear Low
4 2. Gear High
5 3. Gear Low
6 3. Gear High
Range High ist engaged
7 1. Gear Low
8 1. Gear High
9 2. Gear Low
10 2. Gear High
11 3. Gear Low
12 3. Gear High

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Tips for service:

Compared to the Actros, no splitter arrows are shown in neutral position in the Axor with
Mercedes PowerShift 1. These are only visible when the power take-off is activated.

Display of the clutch overload warning:

With a heavy load on the clutch (e.g. with extended maneuvering under load), the clutch
components are under stress due to the increased operating time in drag range. The driver is
notified of this situation by means of a visual as well as an acoustic message. This is a pure
component protection function that is not accompanied by any functional impairments.

TIPS for service:

On vehicles with corresponding use profiles (e.g. refuse vehicles), the stress in the drag range can
be reduced by the determination (parameter in the FR/CPC control unit) of a fixed start-off gear
(see SI 30.35-W-0002A).

Current, service-relevant information on the Mercedes PowerShift can also be found in

TIPS or in WIS.

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