Body/equipment

Model designations 950 – 954 mounting directives

1998 edition
These directives apply as instructions for the production
and mounting of bodies and equipment not manufactured by
Mercedes-Benz and for the fitting and installation of ancillar-
ies.
The specifications listed must be observed exactly to ensure
operational and road safety of the chassis and maintain the
warranty conditions.
Daimler-Benz AG assumes no liability whatsoever upon fail-
ure to comply with these directives.
Illustrations and schematic drawings are examples and
serve to explain the texts and tables.
References to directives, standards, guidelines, etc. are
in brief form for information only.
Notes concerning vehicle safety
We recommend:
– Using only Mercedes-Benz original parts and conversion
parts and accessories expressly approved by Mercedes-
Benz for the vehicle model in question.
These parts have been subjected to special tests for deter-
mination of their safety, reliability and suitability.
We cannot be held liable for reliability, safety and suita-
bility if:
– Original parts, approved conversion parts and accessories
have been replaced with other parts or if other modifica-
tions have been made to the vehicle.
– Bodies have not been produced or installed in compliance
with current Mercedes-Benz body/equipment mounting di-
rectives or upon failure to obtain Mercedes-Benz approval
in the event of deviation from these directives.
Approval granted by public testing agencies or official organi-
sations does not exclude safety hazards.
Further information is available from any Mercedes-Benz
Service Station.
Daimler-Benz Aktiengesellschaft

Printed in Germany
We reserve the right to make changes without notice.
Not to be reprinted, reproduced or translated, in whole or in part, without
written permission.
Title illustration: N00.00-2104-24C
Print date: 29.05.98
VSE/6.98.10 K

H Printed on paper bleached without chlorine

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Contents
Page Page
1 General ................................................... 5 2.8 Retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.1 Vehicle and model designations . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.9 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Explanation of model designation . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.10 Engine air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2 Granting of body/equipment approvals and technical 2.11 Steerability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
counselling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.12 Leading axle/trailing axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 Body equipment approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.13 Bolted connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3.1 Granting of body approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.14 Welded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.3.2 Legal claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.15 Special equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4 Drawings of products offered, technical data 2.16 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
and product information brochures . . . . . . . . . . . . . . . . . . . . . . . 8
2.17 Free space for assemblies and cab . . . . . . . . . . . . . . . . . . . . . . . 26
1.5 Product liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.18 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.6 Warranty claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.19 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.7 Mercedes star and emblem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.20 Pneumatic auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.8 Maintenance instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.21 Retrofitting an automatic transmission . . . . . . . . . . . . . . . . . . . 29
1.9 Corrosion protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.22 Maintaining the permissible total operating height . . . . . . . . . 29
1.10 Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.11 Reprocessing of components – recycling . . . . . . . . . . . . . . . . . . 14 3 Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.12 Recommended quality management system . . . . . . . . . . . . . . . 15 3.1 Plastic compressed air lines and brake hoses. . . . . . . . . . . . . . 30
3.2 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 Planning of bodies ...................................... 16
3.3 Leaf springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1 Vehicle modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Paintwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2 Dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5 Tilting the cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3 Vehicle overhang and technical wheelbases . . . . . . . . . . . . . . . 17
3.6 Towing and tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4 Weight distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.5 Centre of gravity heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.8 Mobile communication systems . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.6 Stabilisers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.9 Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.7 Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.10 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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 Page Page
4 Chassis frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1 Material for chassis frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.1 Power supply – auxiliary loads. . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.2 Reinforcements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.1.1 Electrical consumers up to 10 ampères . . . . . . . . . . . . . . . . . . . 57
4.3 Drilling holes in frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 6.1.2 Electrical consumers over 10 ampères . . . . . . . . . . . . . . . . . . . 59
4.4 Welding on the frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.2 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.5 Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6.3 Installation of lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.6 Wheelbase modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 6.4 Anti-theft alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.6.1 Modifying the wheelbase by moving the rear axle . . . . . . . . . . 41
4.6.2 Modifying the wheelbase by cutting the longitudinal frame 7 Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 7.1 Use of vehicle with centre-axle trailer . . . . . . . . . . . . . . . . . . . . 65
4.6.3 Approval of modification to wheelbase . . . . . . . . . . . . . . . . . . . . 43 7.2 Lowered trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.6.4 Propeller shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.7 Modifications to the frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 8 Mounting frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.7.1 End cross member. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 8.1 Material quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.7.2 Frame extension – standard chassis . . . . . . . . . . . . . . . . . . . . . . 48 8.2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.8 Detachable parts and auxiliary equipment. . . . . . . . . . . . . . . . . 50 8.3 Channel dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.8.1 Mounting on chassis frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 8.4 Floor assembly as mounting frame . . . . . . . . . . . . . . . . . . . . . . 75
4.8.2 Chocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 8.5 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.8.3 Wings and wheelhouses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 8.5.1 Friction-locking connection – console mounting . . . . . . . . . . . 78
4.8.4 Spare wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 8.5.2 Form-locking rigid connection – butt strap joint . . . . . . . . . . . 80
4.8.5 Rear underride guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 8.5.3 Quick-release lock for interchangeable bodies . . . . . . . . . . . . . . 81
4.8.6 Side underride guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.1 Attachments above cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 Spoilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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 Page Page
9 Types of bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 10 Loading tailgates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
9.1 Self-supporting bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.2 Platform, van, box-type and interchangeable bodies. . . . . . . . . 83 11 Semitrailer tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
11.1 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
9.3 Loading cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9.3.1 Loading crane mounted behind cab . . . . . . . . . . . . . . . . . . . . . . 85 11.2 Semitrailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
9.3.2 Rear-mounted loading crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 11.3 Connections for brake system and electrical system . . . . . . . 112
9.3.3 Removable loading crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 11.4 Semitrailer tractor chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.3.4 Vehicles with lifting trailing axle (lifting axle) . . . . . . . . . . . . . 95 11.5 Semitrailer tractor with standard chassis . . . . . . . . . . . . . . . . 116
9.4 Dump truck bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 11.5.1 Necessary chassis frame conversion measures . . . . . . . . . . . 116
9.4.1 Special tilting bodies on standard chassis . . . . . . . . . . . . . . . . . 98 11.5.2 Mounting frame and semitrailer coupling. . . . . . . . . . . . . . . . 116
9.5 Tank and dry bulk bodies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
9.5.1 Tank and dry bulk bodies without continuous 12 Programmable special module (PSM). . . . . . . . . . . . . . . 118
mounting frame 102
9.5.2 Platform-mounted tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
13 Power take-offs ....................................... 122
13.1 Transmission-dependent PTOs . . . . . . . . . . . . . . . . . . . . . . . . . 124
9.6 Vehicles for transport of hazardous goods . . . . . . . . . . . . . . . 103
13.2 Dump truck pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.7 Vehicles for transport of aggressive substances . . . . . . . . . . . 104
13.3 Power take-offs at front of engine. . . . . . . . . . . . . . . . . . . . . . . 128
9.8 Truck-mounted cement mixers . . . . . . . . . . . . . . . . . . . . . . . . . 104
13.4 Power take-offs at rear of engine . . . . . . . . . . . . . . . . . . . . . . . 129
9.9 Winter road service vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
13.5 Installation of propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.10 Roll-off and removable dump truck bodies . . . . . . . . . . . . . . . . 105
9.11 Other bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133

4
1 General
1.1 Vehicle and model designations
These body/equipment mounting directives apply to the following vehicles:
Vehicle Model Internal designation Model designation

ATEGO 1823 - 2628 SKN-R 950. – 954.

Explanation of model designation:

Example 2528 L 6x2 /4
25 Permissible gross weight in tonnes (solo vehicle)
28 Engine output in HP (≈ x 10)
L Vehicle version (short designation)
Chassis/platform truck
A All-wheel drive
B Cement mixer
K Dump truck
S Semitrailer tractor
L Pneumatic suspension
6x2 /4 Axle designation
6 Number of wheels or wheel pairs
x2 Number of driven wheels or wheel pairs
/4 Number of steered wheels

5
 1.2 Granting of body/equipment approvals and technical counselling
The employees in department EL/LK issue body approvals and answer technical design
questions on registration of vehicles and product liability.
The responsible employees can be reached by:
Telephone: +49-7 11/17 - 5 84 25
+49-7 11/17 - 5 44 15
+49-7 11/17 - 5 17 19 for basic questions
Fax: +49-7 11/17 - 5 21 91
Post address: Daimler-Benz AG, HPC B208 (in-house post code),
Department EL/LK, D-70546 Stuttgart, Germany
In addition, current information is available from our fax call-up system.
The title page with the list of contents can be called up on fax number
+49-7 11/17 - 8 52 50 00.
Body approvals for vehicle use outside of Germany can be obtained from:
Daimler-Benz AG, HPC Z604,
Department VL/MA, D-70546 Stuttgart, Germany
Fax: +49-7 11/17 - 9 09 67

1.3 Body equipment approval

All work performed on the chassis and body must be accomplished in accordance with
MB body/equipment mounting directives.
Body/equipment approval from Daimler-Benz AG is required only when:
– The body/equipment is not produced in accordance with MB body/equipment mount-
ing directives.
– The permissible axle loads are exceeded.
– The maximum gross weight is exceeded.

6
1.3.1 Granting of body approval
Submit three drawings of the body to the department specified above for approval. The
following information must be given:
– All deviations from MB body/equipment mounting directives.
– Complete data on dimensions, weights and centre of gravity.
– How the body is attached to the chassis frame.
– Conditions under which the vehicle is intended to be operated, e.g.:
operation on poor roads,
in very dusty conditions,
at high attitude,
at extremely high or low ambient temperatures.
Questions can be avoided and the approval procedure accelerated by providing com-
plete documentation.

1.3.2 Legal claims

– In principle there is no legal obligation for granting body approval.
– Daimler-Benz retains the right to refuse approval due to technical progress even
when similar approval has been granted previously.
– The body equipment approval can be limited to single vehicles.
– Subsequent granting of an approval for vehicles already completed or delivered may
be refused.
The body manufacturer is responsible for
– the functional operation of his bodies and/or equipment,
– all modifications and installed parts not indicated or indicated insufficiently in the
document submitted.

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 1.4 Drawings of products offered, technical data
and product information brochures
Offer drawings and technical data are available from MB-AS or for:
– vehicles used in Germany, from
Daimler-Benz AG, Department PES, Postfach 20, D-76742 Wörth
Fax: +49- 72 71/71 - 55 14.

Mercedes-Benz body/equipment manufacturer system MB-AS

The Mercedes body/equipment manufacturer system MB-AS is a modern communica-
tions system for exchanging offer drawings, technical data and product information on
all commercial vehicles.
Current commercial vehicle information and data can be called up with a minimum of
expense, either in fax or data format, by modem or by ISDN data transfer, and can then
be printed and processed.
You are thus optimally equipped to give your customers quick, low-cost and comprehen-
sive advice, for feasibility studies and for determining the final vehicle concept, for com-
piling a quotation and for design.

8
PC programme (ISDN/modem)
The desired vehicle information can be selected and ordered directly with easy-to-use
selection catalogues in this Windows programme.
The following are available:
– Offer drawings in CAD formats IGES, DXF and DWG
and in Pixel format (DIN A4 size).
– Technical data sheets
– Body/equipment mounting directives.
– Body manufacturer information.
– Power take-offs.
The data can be transferred within a few minutes via ISDN or modem.

Fax call-up system

Vehicle data can be called up and printed out with the aid of any fax machine with built-
in "call-up" function. Additional information on this is given in the manual for the fax
machine.
After selecting the call-up function and entering the number +49-7 11/17 - 86 40 40 you
first receive the MB-AS title page containing all information categories and call-up num-
bers for the table of contents. In total approx. 1,500 technical sheets and over 3,000 offer
drawings as well as information for the body manufacturer can be called up.
All vehicle information available using the PC programme and services associated with
the fax call-up system are free of charge.
Additional information on MB-AS is available under the telephone number
+49-7 11/ 17- 4 11 14

9
 1.5 Product liability
Legal product liability means the liability of a manufacturer for subsequent damage re-
sulting for the user of the product or a third party when the product does not possess
the degree of safety or reliability in use which can normally be expected by the party
injured.
Please note the following points with regard to product liability:
– Each manufacturer is liable for his own product.
– Daimler-Benz AG is excluded from any liability for damages resulting from faults in
subsequently attached or installed products from other manufacturers.
The body/equipment manufacturer is liable for:
– the safety and roadworthiness of the body,
– safety and roadworthiness of parts and conversions not listed in the documents sub-
mitted,
– operational reliability and roadworthiness of the vehicle (the body and/or equipment
must not have a negative effect on the driving, braking or steering characteristics of
the vehicle),
– effect of parts or conversions on the chassis when such parts or conversions were not
indicated in the documents submitted,
– subsequent damage resulting from the attachment, installation or conversion,
– subsequent damage resulting from the retrofitting of electrical and electronic sys-
tems,
– The functional reliability and freedom of movement of all moving parts of the chassis
(e.g. axles, springs, propeller shafts, steering, transmission linkage, retarder, etc.) as
well as for diagonal twisting in relation to the bodies.
Work or modification performed on the chassis or body must be entered in
the Maintenance Booklet under the section "Confirmations by the body manufac-
turer".
The body manufacturer must release Daimler-Benz AG from all liability for damage re-
sulting from:
– failure to observe these directives,
– faulty design, production or installation
– failure to comply with the principles specified in any other manner.

10
Within the scope of these directives information on product liability can only be provid-
ed in general form. Detailed information is given in the publication "Body Manufactur-
er Information", Edition August 1990, which can be requested from Daimler-
Benz AG, HPC Z 225, Department MBVD/VNL, D-70546 Stuttgart, Germany.

1.6 Warranty claims

Warranty claims can only be made within the scope of the sales contract between the
purchaser and seller. This means that each seller warrants the items supplied by him to
the purchaser.
Daimler-Benz AG assumes no liability
– in the event of failure to comply with our body/equipment mounting directives.
– when the chassis used does not correspond to the equipment version for the country
in question and area of application,
– for damage to the chassis caused by the body itself or the manner in which it
is mounted.
Whenever possible, avoid asymmetrical loading of the chassis when attaching equip-
ment and bodies. If asymmetrical loads are unavoidable (e.g. loading crane mounted on
one side, glass transport frame, generator set, auxiliary tanks, etc.) approval by the re-
sponsible department is required.
For vehicles with extreme modifications to the wheelbase and with bodies for loads with
an unfavourable centre of gravity (e.g. centre of gravity at rear, extremely high or at
side) Daimler-Benz cannot provide information on the handling, braking and steering
characteristics of the vehicle. In such cases the body manufacturer is responsible for the
roadworthiness of the vehicle.

11
 1.7 Mercedes star and emblem
The Mercedes star and MB emblem are trademarks of Daimler-Benz AG.
– They may not be removed or attached to another point without approval.
– Mercedes-Benz stars and MB emblems supplied separately must be attached at the
points specified by Mercedes-Benz.
If the vehicle fails to reproduce the customary MB vehicle image or fails to meet the
quality requirements demanded of MB vehicles:
– The trademarks must be removed
– The body manufacturer becomes the manufacturer of the entire vehicle in terms of
legal product liability and assumes the entire liability.
Third party trademarks
– may not be attached in the direct vicinity of MB trademarks,
– may only be attached with the approval of the responsible department.

1.8 Maintenance instructions

The following must be observed by the body/equipment manufacturer before delivery
of the vehicle:
– Inspections must be performed by a Mercedes-Benz Service Station when due.
– Check headlamp adjustment or have it checked by a Mercedes-Benz Service Station.
– Have automatic load-dependent brake (ALB) checked in a Mercedes-Benz Service Sta-
tion or a specialist workshop.
– Check condition and capacity of battery and service according to manufacturer's
specifications.
– Retighten wheel nuts, observe tightening torque.
Operating and maintenance instructions for the body work performed and other
equipment installed must be included with vehicle.

12
1.9 Corrosion protection measures
Avoid welding work on inaccessible cavities.
Following all work on vehicle
– remove chips from drilling.
– deburr sharp edges.
– remove burned paint.
– prime all bare parts and paint.
– preserve cavities with wax preservative.

1.10 Accident prevention

The body manufacturer is responsible for damage
– resulting from insufficient reliability or safety of the body or parts supplied by him.
– resulting from errors or deficiencies in the operating instructions for the body or
parts supplied by him.
The body and attached or installed equipment must comply with the applicable
laws, labour protection and accident prevention regulations of the municipal in-
surance carrier. All technical possibilities for avoiding unsafe operating condi-
tions must be utilised.
In Germany information is available for commercial carriers from the vehicles section
of the "Fachausschuß für Verkehr" at the Berufsgenossenschaft für Fahrzeughaltung
(Traffic Committee of Professional Society for Vehicle 0wnership), D-22757 Hamburg
(Tel. +49 - 40 - 3980-0, Fax +49-40-3980-1999).
Observe all specific national guidelines and regulations.
The body and equipment manufacturer is responsible for compliance with these
laws and regulations.
Observe operating instructions before tilting the cab!

13
 1.11 Reprocessing of components – recycling
When planning the bodies or equipment, the following principles for environmentally
suitable design and material selection should be taken into account, particularly with
regard to expected legal regulations right up to the obligatory recycling by the manufac-
turer.
– Avoid using materials with risk potential such as halogen additives, heavy metals, as-
bestos and CFCs.
– Preferably use materials which permit recycling and closed material cycles.
– Select materials and the production process so that only slight quantities of waste
which cannot be properly recycled are generated during production.
– Use plastics only where they provide advantages in terms of cost, function or weight.
– In the case of plastics, in particular in the case of composite materials, use compatible
substances within one material family.
– For components which are relevant to recycling, keep the number of different types
of plastics used to a minimum.
– Check whether a component can be made from recycled material or with recycled ad-
ditives.
– Ensure that the components can be dismantled easily for recycling e.g. by snap con-
nections, artificially weakened points, good accessibility, use of standard tools.
– Ensure that industrial fluids can be removed simply and in a manner compatible with
the environment by means of drain plugs, etc.
– Wherever possible, refrain from painting and coating components, use pigmented
plastic parts.
– Design components in areas endangered by accident so that they are damage-toler-
ant, repairable and easy to replace.
– Mark plastics according to VDA guideline 260, e.g.,
PP - GF30R.
Additional information is given in the brochure "Commercial vehicle recycling, ecology
and economy", order no. 6702 6187 00-00/0592.

14
1.12 Recommended quality management system
Worldwide competition, increased quality requirements placed on the entire truck
by customers, national and international product liability laws, new organisational
forms and increasing cost pressure require effective quality management systems in all
areas of the automotive industry
To reflect these demands, a working group of the VDA has developed the "Guide to qual-
ity assurance for the manufacturers of trailers, bodies and containers, which was pub-
lished as VDA Volume 8, on the basis of DIN EN ISO 9000 ff.
Within the scope of close cooperation between the chassis and the body manufacturer,
commercial vehicle manufacturers recommend the establishment of a quality manage-
ment system with the following minimum requirements for the reasons given above:
– Development, establishment and auditing of a quality management system in the
company in question.
– Designation of responsibilities in an organisational plan.
– Designation of a quality manager.
– Ensuring that processing, working and testing instructions are available and up to
date in all areas and at all work stations.
– Fulfillment of required qualification tests for all affected employees.
– Documentation and archiving of required quality assurance measures for the prod-
uct.
– Availability of suitable test equipment (e.g. torque wrenches) and supervision of con-
tinuous test equipment monitoring
– Introduction of internal audits for the quality management system and product qual-
ity.
This list makes no claim to completeness; the primary purpose is to reiterate to commer-
cial vehicle manufacturers the main facets of a functioning, recognised quality manage-
ment system, as described, for example, in VDA Volume 8.

15
 2 Planning of bodies
Before starting work on the body:
– Check whether the chassis is suitable for the planned body;
– Check whether the chassis model and equipment are suitable for the conditions of
use.
Offer drawings and technical data for planning bodies can be requested from the respon-
sible department.

2.1 Vehicle modifications

Vehicles supplied from the factory correspond to EC guidelines and national regulations
(except for some vehicles for non-European countries).
After completion of the modifications, the vehicles must comply with the EC
guidelines or national regulations.
Modifications to the steering system, brake system and the noise encapsulation system
are not permissible (except modifications to the wheelbase or frame).
Vehicle approval:
– The officially recognised approval official or tester must be informed by the body
manufacturer of any modifications to the chassis.
– Submit Daimler-Benz approval (e.g. drawing with approval mark) or applicable body/
equipment mounting directive if required.

2.2 Dimensions and weights

Dimensions and weights are specified in offer drawings and the technical data. These
are based on the standard vehicle equipment. Note that weight tolerances allow up to
+ 5% (in Germany according to DIN 70020).
Do not exceed permissible axle loads and gross vehicle weights listed in the technical
data.
Information on changes in the weight is available from the responsible department.

16
 2.3 Vehicle overhang and technical wheelbases
Always take permissible axle loads and minimum front axle loads into consideration
when determining the length of the overhang
Take the special equipment into consideration when calculating the weight.
Maximum vehicle overhang (Ü)
Two-axle vehicles 65% of wheelbase
R Ü
Three-axle vehicles 70% of technical wheelbase
On some models an extended frame overhang is available ex factory as special
equipment (code CR2 and CR3)
Technical wheelbases (Ri)
Observe national regulations and guidelines.

2.4 Weight distribution

R
Ri Ü Avoid one-sided weight distribution.
The wheel load (½ the axle load) should not be exceeded by more than max. 4%.
Observe tyre load capacity.
Example: Permissible axle load 10,000 kg
Permissible wheel load distribution 5,200 kg to 4,800 kg

R
Ri Ü

R = Wheelbase
N00.00-2108-22 Ri = Technical wheelbase
N00.00-2108-22 Ü = Overhang

17
 2.5 Centre of gravity heights
Calculations showing proof of the height of the centre of gravity with the vehicle laden
must be provided for approval of a vehicle with body according to the EC guideline
"Brakes" 71/320 EEC. Calculation bases and the permissible height of the centre of grav-
ity can be requested from the responsible department.
Daimler-Benz cannot provide any information on the driving, braking and steering char-
acteristics of bodies for loads with unfavourable centre of gravity locations (e.g. rear,
side, height). In such cases the body manufacturer is responsible for the roadworthiness
of the vehicle.
2.6 Stabilisers
When ordering the vehicle pay attention to the correct equipment.
Loads:
Centre of gravity (A) above top of chassis frame
up to 550 mm normal load
550 – 1,250 mm high load
over 1,250 mm extremely high load

N32.35-2001-22
N32.35-2001-22

18
 2.7 Tyres
The body manufacturer must ensure that
– the largest permissible tyres can be installed,
– the distance between the tyre and the wing or wheelhouse is sufficient even when
snow or anti-skid chains are mounted and the suspension is completely compressed
(also including any frame twist).
Observe specifications in offer drawings.
Caution!
– On vehicles with Telligent® brake system (BS) the parameters must be reset for the
brake system any time the tyre size is changed. Otherwise the braking characteris-
N43.40-0202-20 tics of the vehicle can change. Information is available from any Mercedes-Benz
Service Station.

A Inner mount
B Outer mount
1 Silent block
2.8 Retarder
2 Reinforcement plate Approval is required from the responsible department for retrofitting a retarder on the
transmission or the propeller shaft train. General approvals are not granted; approvals
are always limited to certain vehicle model designations and wheelbases.
The installation drawings must include the following information:
– Position of retarder in vehicle,
– Propeller shaft angle,
– Length of propeller shaft.
– Owing to the additional weight of the retarder, check weight distribution and main-
tenance of the permissible axle loads. Moreover, check the position of the centre of
gravity of the body or distance between rear axle and semitrailer coupling point, and
adapt if necessary.
– Installation is permissible only in vehicles with sufficiently dimensioned electrical
system (generator and batteries with sufficient capacity).
Ensure that the ground connection for the retarder is sufficient.
– Pay attention to sufficient freedom of movement.

19
 – Mount retarder in the propeller shaft train only on the web of the chassis frame above
the brackets with silent blocks.
– Insulate lines as required to protect against heat. The maximum permissible temper-
ature for polyamide compressed air lines is 80 °C.
– When the retarder is attached to the transmission and body with a frame/floor sys-
tem or with a mounting frame with a height less than 80 mm it is necessary to replace
the plastic lines with steel lines or to route them outside the frame in the area of the
retarder.
It is only permissible to retrofit a retarder on vehicles with the programmable special
module (PSM). Corresponding preparations are available from the factory (see notes on
page 118).
The retarder should be connected to the PSM and the parameters set as required. Addi-
tional information is available from any Mercedes-Benz Service Station.

2.9 Cooling
It is not permissible to modify the cooling system (radiator, radiator grille, air ducts,
coolant circuit, etc.).
A sufficient quantity of cooling air must be ensured.
– Keep the radiator air inlet clear.
– Do not attach warning signs, plates or other ornamental parts in the area in front of
the radiator.
Provide for additional cooling devices for assemblies
– when operating at ambient temperatures over 35 °C,
– with vehicle stationary and supplying high continuous output.

20
2.10 Engine air intake
Observe the following for modifications to the engine air intake:
– Standard parts such as the air cleaner, rain caps, hoses, mounts (vibration insula-
tion), etc. must be installed in a manner equivalent to the standard state to ensure
proper operation.
– The flow speeds in the intake area in front of and in the air intake duct must not be
increased. Do not restrict free cross-sections.
– No modifications are permissible to the pure air side or the maintenance indicator
connection.
– Connection points on the pure air side must be 100% gas-tight.
– Connection points on the unfiltered air side must be dustproof and watertight.
– Do not modify the installation conditions in the area of the intake opening.
– Do not install the air intake in the turbulence area of the cab or body.
– Position intake openings in zones with low quantities of dust road spray.
– Use suitable measures to protect intake openings from ingress of rain and spray as
well as protecting against water running off cab. If necessary, provide for water sep-
aration.

21
 2.11 Steerability
A minimum front axle load must be maintained in all load states to ensure sufficient
steerability of the vehicle. Confirm with responsible department in the event of devia-
tions.

Vehicle Minimum front axle load

Atego 25% of gross vehicle weight

2-axle vehicles
------------------------------------------------------------------------------------------------------------------------------
with loading tailgate,
crane on rear of vehicle,
or operation with single-axle trailer
(centre-axle trailer) 30% of gross vehicle weight
------------------------------------------------------------------------------------------------------------------------------
Operation with centre-axle trailer
Tractor/trailer ratio > 1:1 35% of gross vehicle weight
------------------------------------------------------------------------------------------------------------------------------
2 and 3-axle vehicles – solo operation
3-axle vehicles 6x2
without assemblies on rear of vehicle 22% of gross vehicle weight
no operation with centre-axle trailer (in exceptional cases only,
not with centre of gravity for high load comply with instructions below)

GRisk of accident!
– Do not exceed the permissible axle load.
– Loading the vehicle towards the rear significantly impairs the handling charac-
teristics – drive with particular care and attention.

22
2.12 Leading axle/trailing axle
Approval by the responsible department is required for retrofitting a leading or
trailing axle.
Before installing take the following factors into consideration:
– A stabiliser is required on the live axle.
– Additional frame reinforcement must be installed.
– Changes in the load introduction points (e.g. axle suspension, spring assemblies,
etc.) are not permissible.
– The minimum front axle load must be maintained in accordance with increasing
gross vehicle weight.
– The permissible front axle loads must not be exceeded.
– The braking effect of the service and parking brake on the leading or trailing axle
must be matched to the standard brake system (brake cylinders, linkage adjustment
lever length, brake linings). Larger brake cylinders may be required on the front axle.
– On vehicles with Telligent® brake system/ABS the leading or trailing axle must be
attached to the rear axle side for side in terms of the brakes and, if necessary, the
brake pressure must also be reduced for ABS operation.
– The legally specified actuation and threshold times must not be exceeded.
– The volume of compressed air for the rear axle brake circuit must be
increased accordingly.
– On vehicles with traction control on the leading or trailing axle the brake control
must be adapted accordingly.
– On vehicles with acceleration skid control (ASR) suitable measures must be taken to
prevent the leading or trailing axle from being braked in the ASR mode.
– The specified effect of the exhaust brake must be achieved following the load in-
crease.
– The air compressor output must be adequate.
– The layout of the automatic load-sensitive brake pressure control and overload pro-
tection devices must be adapted.

23
 – The leading or trailing axle must be mounted on the chassis frame in such a manner
that the longitudinal and lateral forces can be absorbed with certainty without trans-
ferring these on to the live axle.
– Ensure that a sufficient distance is maintained to the propeller shaft.
– Use a uniform suspension system with axle load compensation wherever possible.
– Give preference to vehicles with increased permissible front axle load.
2.13 Bolted connections
If it is necessary to replace standard bolts, use only bolts
– with the same diameter,
– with the same strength class,
– of the same type,
– with the same thread pitch.
When converting bolted connections from DIN (DIN 960) to ISO (DIN EN 28 765) ex-
tremely high surface pressures occur in the contact area which can lead to plastic defor-
mation and a reduction in the initial tightness. For this reason we recommend installing
high tensile strength washers (material such as CrMo4) beneath the bolt and nut.
We recommend using flat-head bolts and flange nuts according to Mercedes-Benz stand-
ards 10105, 10112 and 13023.
The tightening torques can be taken from the body/equipment manufacturer informa-
tion bulletin dated 22.7.96, which can be ordered via MB-AS. Procurement sources for
these flat-head bolts remain listed in MB-AS. The flat-head bolts are fitted with a clamp-
type lock and should therefore only be used once.
On some vehicles huck spin mounting elements are used on the spring support and on
the centre bearing. These can be unscrewed and replaced with the appropriate tools. If
such tools are not available the huck spin bolts can be replaced with bolts (14 mm huck
spin by thread M16, 16 mm huck spin by thread M18). Use only flat-head bolts or, in the
area of the centre bearing, self-locking bolts.

24
2.14 Welded connections
Welding is not permissible:
– On the assemblies such as the engine, transmission, axles, etc.
– On the chassis frame (except for wheelbase and frame modifications).

2.15 Special equipment

Special equipment (e.g. heavy-duty springs, frame reinforcement, auxiliary tanks, stabi-
lisers, etc.) increases the unladen weight of the vehicle.
– Weight data on the special equipment is available from the responsible department.
– Determine the actual chassis weight by weighing before installing the body or equip-
ment.
Equipping the chassis with different springs or tyre sizes can significantly change
the frame height in the laden or unladen state.
It is not possible to install all special equipment on any chassis without problems. This
applies particularly to retrofitting.

2.16 Noise insulation

– If parts relevant to noise are modified (e.g. engine, exhaust system, air intake system,
tyres, etc.), noise measurements are to be taken.
Observe national regulations and guidelines.
In Germany, EC guidelines 70/157/EEC or Sec. 49.3 StVZO (low noise) apply.
– Do not remove or modify parts installed as a standard feature for noise insulation.

25
 2.17 Free space for assemblies and cab
1
Certain free spaces must be maintained in order to ensure the operation and safety of
the equipment.
Observe the dimensions specified in the offer drawings.
Gearshift linkage
– Sufficient distance to body even with cab tilted.
2 – Observe vertical swivelling area of semitrailer.
N00.00-2106-20 Spring-loaded brake cylinder
– On vehicles with drum brakes ensure adequate clearance and accessibility for
the spring-loaded brake emergency release screw.
Engine, transmission, retarder
– Minimum distance to body 30 mm.
N00.00-2106-20
Cab
Clearance – The distance between the cab and the body or exhaust pipe must be at least 50 mm.
1 Tilting the cab On temperture-sensitive bodies, a heat shield should be installed.
2 Gearshift linkage
Free space for tilting cab:
Vehicle Cab A B
B -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------
ATEGO Short (F07) 1,440 405
Short with extension (F20) 1,440 450
Long (F04) and 1,440 860
Long-high (F04+DD5)
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------
N00.00-2107-20 On vehicles with short cab, ensure sufficient height of mounting frame.

A N00.00-2107-20

26
 2.18 Maintenance and repair
Maintenance and repair of the vehicle must not be obstructed by the body any more
than absolutely necessary.
Maintenance points and assemblies must be easily accessible.
– Install maintenance flaps or removable rear walls on stowage compartments.
– The battery compartment must be sufficiently ventilated with provisions for air to
enter and exit.
– Observe vehicle operating instructions.
Additional work resulting from the body for warranty, maintenance or repair will be
N49.10-0358-20 charged by Daimler-Benz AG.

2.19 Exhaust system

Torsional radii – Use only Mercedes-Benz original parts for modifications to the exhaust system.
– It is not permissible to change the length or installed position of the flexible metal
hose between the exhaust manifold and the exhaust pipe.
– Do not reduce the free cross section of the exhaust pipe behind the silencer.
– Minimum distance to plastic lines, electric cables and spare wheels:
200 mm for exhaust system without shielding,
80 mm for sheet metal shielding,
40 mm for sheet metal shielding with additional insulation.
If it is not possible to maintain these distances, replace plastic lines with Tombak
steel tubing according to DIN 1755, material CuZn 20 F 33, with same inner diame-
ter.
– Additional shielding is required:
In the area of control elements.
N49.10-0359-20 In the area of assemblies, attachment and installed parts of materials not resistant to
heat.

27
 2.20 Pneumatic auxiliary equipment
If pneumatic auxiliary equipment is installed:
– Auxiliary equipment with high or constant air consumption:
Install auxiliary air compressor (if possible take into consideration when ordering ve-
hicle).
– Additional loads with low air consumption (e.g. shifting cylinders) can be connected
22 21 directly to the four-circuit protection valve connection 24 and protected by an addi-
26 25 tional overflow valve (popen =7.5 bar).
The compressed air circuits are secured against one another by four overflow valves
with limited return flow inside the four-circuit protection valve.
24 23 Auxiliary loads should be connected only to the four-circuit protection valve at
N42.60-0207-20 connection 24. Install a T-fitting in the compressed air line if required.
N42.60-0207-20
Connections four-circuit protection valve
21 Brake circuit I
22 Brake circuit II
23 Trailer
24 Engine brake and auxiliary loads
25 Spring loaded cylinder
26 Clutch control and transmission shifting
The tanks must be tested to EC guidelines for simple pressure tanks
(87/404/EEC), operating instructions must be provided.

28
2.21 Retrofitting an automatic transmission
Approval of the responsible department is required before retrofitting an automatic
transmission.
On vehicles with Telligent® brake system (BS), it is not possible to retrofit an automatic
transmission.

2.22 Maintaining the permissible total operating height

On vehicles with low frame height and pneumatic suspension (large volume transport-
ers) it is possible to set a higher operating position to improve the suspension comfort.
This is indicated by a display on the instrument panel. This compensates for compres-
sion of the tyres when the vehicle is laden.

Caution: Take legal regulations on permissible vehicle height (4 m in Germany)

into consideration when planning bodies. Observe vehicle operating instructions.

29
 3 Accident prevention
3.1 Plastic compressed air lines and brake hoses
Before welding, drilling, grinding or work with cutting discs
– cover plastic lines and brake hoses
– remove, when necessary,
– check system for pressure loss after installing the lines.
Routing the lines along the brake hoses
– The lines must not touch the brake hoses.
Use spacers.

3.2 Welding work

The following safety measures must be observed to prevent damage to electronic com-
ponents resulting from excessive voltage during arc welding work:
– Have welding work for the chassis frame performed only by trained personnel.
– Disconnect positive and negative terminals on battery and cover.
– Connect ground clamp for arc welder directly to the part to be welded. Ensure that
welding current never passes through electronic components by indirect routes.
Caution! Do not contact arc welder ground clamp to assemblies (engine, transmis-
sion, axles)
– Do not touch electronic component housings (e.g. control units) and electric lines
with welding electrode or ground contact clamp of arc welder.
N00.01.0220-22 – Before welding cover springs and air bellows to protect from welding beads. Do not
contact springs with welding electrodes or welding tongs.

30
Caution!
When welding on the vehicle do not connect arc welder ground clamp to transmission
or its peripheral equipment. The welding current can lead to arcing in the bearings on
the inside of the assembly. The resulting changes in the structure at the bearing contact
points can clearly be identified as new hardened zones. Such damage can lead to pre-
mature failure of the transmission.
Do not perform welding work on:
– Assemblies such as engine, transmission, axles, etc.
– Chassis frame (except for wheelbase and frame modifications)

3.3 Leaf springs

Parabolic springs
– Damaged parabolic springs must be replaced.
– Spring leaves must not be replaced individually.
– Use only original Mercedes-Benz springs. Reinforcement by installing additional
spring leaves is not permissible.
– Do not damage the surface or corrosion protection on the spring leaves during instal-
lation work.
– Before welding cover the springs to protect against welding beads. Do not touch
springs with welding electrodes or welding tongs.

31
 3.4 Paintwork
The frames and attached parts are finished with a single-component synthetic resin
enamel. Check compatibility of paint before painting over. To avoid colour deviations
when painting bodies, the primer and MB colour numbers used at the factory can be ob-
tained from Daimler-Benz AG, Wörth factory, Department QS/T-O.
Cover the following areas before painting:
– Contact surfaces between disc wheels and brake drums, also between the disc wheels
on vehicles with twin tyres.
– Contact surfaces for wheel nuts.
– Coupling flanges for drive shafts and PTOs.
– Piston rods for hydraulic cylinders (cab hydraulic tilting system, etc.).
– All control valves for the compressed air system.
– Vents on transmission, axles, etc.
– Disc brakes.
Do not exceed a temperature of 80 °C for drying the paint.

3.5 Tilting the cab

Observe operating instructions before tilting the cab!

3.6 Towing and tow starting

Observe operating instructions before towing or tow starting a vehicle.
Caution! Failure to observe the operating instructions can result in
transmission damage.

32
3.7 Electrical system
– Never start the engine when the battery is not properly connected (battery poles
tightened).
– Incorrect polarity of the power supply can damage the control units.
– Never loosen or remove the battery connection terminals with the engine running.
– When the batteries are discharged, the engine can be started with the aid of battery
jump leads and the batteries of another vehicle. Observe operating instructions. Nev-
er use a quick charger for starting.
– Only tow start the vehicle with batteries connected.
– Quick charge batteries only after disconnecting them from the vehicle electrical sys-
tem. Both positive and negative terminals must be disconnected.
Observe vehicle operating instructions.
– Do not disconnect or connect the connectors to the engine control unit (MR) with the
ignition switched on.
– For installation of additional electrical loads, see page 56.
– Provide cables in vicinity of exhaust systems with fireproof jacket.
– Route cables so that there are no chafing points, particularly at crossing points and
sharp edges. If necessary, use cable ducts or guide sleeves.
– Confer with responsible department before retrofitting a main battery switch.
– Do not perform any measurement at the connector contact points with unsuitable
equipment (measurement strips, bare wire ends, etc.). This can lead to contact prob-
lems resulting from the formation of transfer resistances. Use proper test cables.

33
 3.8 Mobile communication systems
When mobile communication systems (e.g. telephone, CB radio) are retrofitted the fol-
lowing requirements must be fulfilled in order to avoid malfunctions on the vehicle
later.
1. Communication equipment
– The equipment must have an FTZ number and comply with DIN VDE 0879, part 2
– The equipment must be permanently installed.
Operation of portable or mobile equipment inside the vehicle is permissible only
when connected to a permanently installed aerial outside the vehicle.
– Install transmitter stage spatially separated from the vehicle electronic system.
– Protect equipment from moisture,
observe permissible operating temperatures,
protect against heavy mechanical vibration.
2. Aerial (for radio equipment)
– Observe manufacturer's notes and installation instructions.
– The aerial must have an FTZ number.
3. Connection and routing
– Connect directly to terminal 30 via additional fuse.
Use a voltage transformer only to supply power to 12 volt equipment on vehicles with
24 volt system.
Disconnect the equipment from the electrical system before jump starting the vehi-
cle.
– When routing lines keep as short as possible (no loops) and twist.
– Ensure that the system has good ground connection to the body (aerial and equip-
ment).
– Route aerial wire, connecting line between the transmitter, receiver and operating
panel with spatial separation to the vehicle wiring harness in the vicinity of the body
ground.
– Do not kink or pinch aerial wire.
– Observe regulations for road transport of hazardous substances (e.g. GGVS and ADR
regulations).

34
3.9 Electromagnetic compatibility
Interference occurs in motor vehicle electrical systems due to individual appliances. At
Mercedes-Benz, electronic components installed at the factory are checked for their
electromagnetic compatibility in the vehicle.
When retrofitting electrical or electronic systems it is also necessary to check their elec-
tromagnetic compatibility.
The following standards provide information on this:
– DIN 40839
– DIN 57879, part 3
– VDE 0879, part 3
– Mercedes-Benz standard 22100
Additional information is available from the responsible department.

3.10 Engine
A warning buzzer is installed where it can be heard by the driver.
The buzzer serves as an acoustic warning when:
– The maximum permissible coolant temperature is exceeded,
– The maximum engine speed is exceeded, etc.
Comply with notes in the operating instructions and supplementary instructions.
If a crane is operated outside the cab (e.g. loading crane), an additional optical warning
display must be installed in the area of control.

35
 4 Chassis frame
4.1 Material for chassis frames
When altering the wheelbase or lengthening the frame, the material for the extension
element and reinforcing bracket must match the standard chassis frame in terms of
quality and dimensions. The material used for the chassis frame is E 500 TM.
4.2 Reinforcements
– Reinforcement brackets must be installed on the inside or outside for modifications
to the wheelbase and frame.
– Screw or rivet reinforcement brackets on and ensure that they end flush with the bas-
N31.30-0223-20 es of the upper and lower cords. Use existing holes in longitudinal chassis frame
member as far as possible.
1 Frame inlay – Sufficient distance must be present on the frame between the top and bottom rein-
2 Reinforcement bracket forcement brackets.

N31.30-0224-20 N31.30-0225-20
Shortening of wheelbase Wheelbase extension
a ≥ 55 mm a ≥ 55 mm

36
 4.3 Drilling holes in frame
Do not drill holes:
– In the top or bottom cord of the chassis frame.
Exceptions are holes at the rear end of the frame. However, these holes may not be
drilled in areas with a supporting function for the last axle or parts fastened to the
frame.
– In the area of sectional changes in the longitudinal frame member such as frame
drops and frame offsets.
– At load introduction points (e. g. directly on the spring supports).
It is not permissible to drill out to a larger size holes already drilled in the top and bot-
tom cord of the chassis frame (exception: mounting holes for end cross member). These
N31.30-0226-20 holes must not be used for fastening assemblies
In special cases holes can be drilled in the web of the longitudinal frame member.
– Distance "a": At least 15% of frame height.
– Hole interval "b": At least 50 mm.
– Maximum hole diameter "d": 18 mm.
Do not introduce force at the centre of the web of the longitudinal member (diaphragm
effect). If this is unavoidable, provide for large surface support on both sides of web.
Deburr and ream out all holes after drilling.

N31.30-0227-20
Holes on longitudinal frame member

37
 4.4 Welding on the frame
Welding work on the frame should always be performed by trained personnel.
Do not weld on the top or bottom cord of the chassis frame
(except when modifying wheelbase or extending frame).
Connect the ground clamp of the arc welder directly to the vehicle part to be
welded.
– Use only completely dry electrodes with basic lime coating. Electrode diameter
2.5 mm.
– Max. current per mm of electrode diameter: 40 A.
– Weld only with electrodes connected to the positive pole of a direct current source.
Always weld from bottom to top.
– MIG welding is permissible.
– Welding wire thickness 1 to 1.2 mm.
– The elongation before break and tensile strength of welding material must be at least
equal to that of the material to be welded.
– Grind welds and reinforce with angular sections to avoid notching from welding.
Avoid welds in bent curves. A distance of at least 15 mm should be present between
the weld and the outer edges.
– Fine grain steels with minimum yield point of > 380 N/mm2 in TM quality and sheet
thickness used for frame parts should not be preheated. Recommended electrodes
with basic jacket:
For E 500 TM: rod electrode DIN 8529 – EY 4664 MoB.

38
4.5 Brake system
After modifications the brake system must be tested and approved by a technical testing
centre.
Air brake system
– Completely replace air brake lines with approved plastic tubing (DIN 74324).
Dimensions: Measuring line dia. 6 x 1
Control line dia. 8 x 1
Supply and brake line dia. 12 x 1.5
Supply line dia. 16 x 2
Use only original Mercedes-Benz line connections.
Modifications to air brake system
(e.g. when modifying wheelbase or frame):
– Use only tubing connection parts and lines approved by us with the same dimen-
sions.
– Thoroughly clean lines before installing.
Routing lines
– Maintain safe distance to heat sources, sharp edges and moving parts.
– Use plastic straps to fasten.
Interval between straps max. 500 mm.
Use of plastic lines is not permissible
– between air compressor and compressed air drier,
– when the ambient temperature is higher than 80 °C,
– in hydraulic systems.

39
 Material
– Plastic lines: Use only polyamide PA 11 PHLY according to DIN 74324, DBL 6270.12.
– Steel tubing: Tombak according to DIN 1755,
material CuZn 20 F 33 or St35NBK olive chromated DIN 50961, DBL 4044.00.
Routing of additional lines along the brake hoses is permissible only after approval by
the responsible department.
After completion of the work check brake system for proper operation.

Bending radii for plastic lines

Tubing dia. Wall thickness Bending radius
mm mm mm
-------------------------------------------------------------------------------------
8 1.0 40
10 1.0 60
12 1.5 60
15 1.5 90
16 2.0 100
18 2.0 110
-------------------------------------------------------------------------------------
The actual radius must be equal to or greater than the specified bending radius.

Disc brakes
– Do not impede cooling by attaching additional spoilers below bumper, hub caps or
brake disc covers, etc.

40
 4.6 Wheelbase modifications
When modifying the wheelbase use a chassis whose standard wheelbase is as close as
possible to the required wheelbase.
Pay attention to changes in the values for the chassis weight and turning circle.
Daimler-Benz AG cannot provide any information on the driving, braking and steering
characteristics of vehicles with extreme modifications to the wheelbase.
We recommend making modifications to the wheelbase by moving the rear axle. This
has cost and weight benefits as there is no need to use reinforcement brackets. If nec-
essary, use vehicles with a lengthened rear overhang.
4.6.1 Modifying the wheelbase by moving the rear axle
N31.30-0223-20 The holes in the longitudinal frame members are positioned at a uniform interval of
50 mm. The rear axle can be moved within this grid after loosening the mounting ele-
1 Frame inlay ments. Holes not already present can be drilled subsequently.
2 Reinforcement bracket Please refer to sections 2.13, bolted connec-
tions, and 4.3, drilling holes in frame.
The position of the cross member must be
adapted to the new position of the rear axle.
If necessary install additional cross members.
It is also necessary to adapt the present frame
reinforcements.

N31.30-0224-20 N31.30-0225-20
Shortening of wheelbase Wheelbase extension
a ≥ 55 mm a ≥ 55 mm

41
 4.6.2 Modifying the wheelbase by cutting the longitudinal frame member
Selecting cutting points so that holes present in the longitudinal frame member are not
cut through.
It is not permissible to cut the frame in the area of:
– Load introduction points
– Axle location points, axle suspension
– Transmission mounting points
– Sectional changes (frame drops, frame offset).
Adapt and weld reinforcement brackets to present inserts according to the position of
the frame cut.
Then bolt reinforcement brackets to chassis frame and frame extension.
After changing wheelbase reinforce chassis with continuous mounting frame.
N31.30-0228-20

Cutting point

N31.30-0229-20 N31.30-2004-22
N31.30-2004-22

Cutting point – Align chassis horizontally before cutting the longitudinal frame member.
– Support frame.

42
Required moment of resistance for mounting frames:
– Up to maximum standard wheelbase:
Please refer to the tables and diagrams in sections 9 – 11 (pages 82 – 117).
– Above the maximum standard wheelbase, increase tightening torque by at least 15%.
– Align chassis horizontally before cutting the longitudinal frame member.
– Support the frame.

4.6.3 Approval of modification to wheelbase

Modifications to the wheelbase which do not go beyond the smallest or highest standard
wheelbase for the relevant vehicle do not require approval. However, the execution
must be in compliance with these body/equipment mounting directives.
Approval is required when:
– Modifications to the wheelbase are greater than the largest or less than the shortest
standard wheelbase.
Approval may be obtained from the responsible department.
Submit application with 3 drawings of the conversion and body with the following in-
formation
– Location of the cut, or new location of the rear axle assembly,
– Reinforcement measures,
– Propeller shaft train,
– Utilisation of vehicle.

43
 4.6.4 Propeller shafts
Proper layout of the propeller shaft train prevents noise and vibrations. If possible, use
original Mercedes-Benz parts.
– When modifying the wheelbase provide for propeller shaft arrangement and propel-
ler shaft length corresponding to a comparable standard vehicle (same model and
same or similar wheelbase).
– The diameter and wall thickness of the propeller shaft tube must correspond to the
standard propeller shaft.
– If necessary use a number of propeller shafts with intermediate bearings.

N41.00-0222-20

Propeller shaft
a Operating length
b Permissible shaft length

N41.00-0223-20 N41.00-0224-20
Intermediate shaft Types of angular displacement
a Operating length

44
– The angular offset must be the same at both joints (β1 = β2).
It must not be greater than 6°. Angular offsets greater than 6° as well as flange angle
errors (β1 < > β2) lead to vibrations in the driving train. This has a negative effect on
the service life of the assemblies and can lead to damage.
– Balance propeller shaft before installation.
– Foamed propeller shafts are used on Atego vehicles.
In exceptional cases send drawings of the intended propeller shaft modification with
precise dimension data (shaft length and displacement angle) to the responsible
department for approval.
All-wheel-drive vehicles
– When modifying the wheelbase, modifications to the propeller shaft are permissible
only downstream of the transfer case.
– The wheelbase may only be shortened down to the shortest standard wheelbase.

45
 4.7 Modifications to the frame
– Modifications to the standard frame overhang are not permissible on semi-
trailer chassis.
– The permissible axle loads must not be exceeded and the minimum front axle load
must be present.
– Rear underride guard: Mounted as on standard vehicle.
– Extend mounting frames to end of frame.
– Check trailer connections for proper operation.
Frame extension
– The interval from one cross member to the next should not exceed 1.2 mm to ensure
adequate torsional stability of the rear frame overhang.
N31.30-0230-20 – The following information is required for checking and approval for operation with
single-axle trailers (centre-axle trailers):
Vehicle
1 Maximum 1,200 mm – Vehicle identification number.
– Body length and body centre of gravity as well as overall length of vehicle.
– Distance from centre of rear axle to coupling point.
– If loading equipment is installed at the rear of the vehicle, the weight of this equip-
ment and centre of gravity in relation to the rear axle.
Centre-axle trailer
– Gross weight.
– Static drawbar.
– H/L ratio from total centre of gravity height above road (H) to distance from coup-
ling point to centre of axle (L).
Shortening the frame
– When shortening the frame at the end move the end cross member to the end of the
remaining frame. If necessary, replace spring cross member with end cross member.

46
4.7.1 End cross member
– An end cross member must always be installed even if operation with trailer is not
intended.
– If a trailer coupling is installed, the necessary reinforcements must be present. Dis-
tance to next cross member min. 350 mm.
– When the rear spring cross member is replaced by the end cross member,
ensure that the mount for the rear spring brackets is not negatively affected.
Please refer to section 2.13, Bolted connections
– Fasten the end cross member as on the standard vehicle.
Bolted version:
Use same number of bolts with same diameter and strength class.
Riveted version:
The rivets can be replaced with fitted or shank bolts
(strength class 10.9) and self-locking nuts.

47
 4.7.2 Frame extension – standard chassis
– The end cross member can be moved up to approx. 250 mm in the direction of the
rear axle. Move gusset plates approx. 350 – 400 mm forward over the welded point.
– When increasing the frame length more than 250 mm, install additional cross mem-
ber.
If the present end cross member is not moved to the rear, install a standard end cross
member in addition.
R Ü With this design the permissible trailer loads specified in the vehicle documents
remain unchanged.
– If the maximum frame overhang is exceeded, the permissible trailer loads specified
in the vehicle documents must be reduced. See diagram. The frame overhang must
be reinforced accordingly.
– Do not use diagram for vehicle application with centre-axle trailer. If the maximum
vehicle overhang is exceeded in this case, the approval of the responsible department
is required.
– Reinforce end cross member in mounting frame and end cross member in chassis
R frame with connection plates.
Ri Ü – Rigidly connect mounting frame to chassis frame between the front rear spring
bracket and end of frame.
Install diagonal cross in mounting frame.

R
Ri Ü

R = Wheelbase
Ri = Technical wheelbase
N00.00-2108-22 Ü = Overhang

48
Permissible trailer load (A)

N31.00-0279-27

Ü
.
R 100 (%)

49
 4.8 Detachable parts and auxiliary equipment
4.8.1 Mounting on chassis frame
– We recommend the use of flange bolts and flange nuts according to Mercedes-Benz
standards 10105 and 13023, material quality 10.9, pitch 1.5 mm, self-locking nuts.
– Use holes already present.
– Adapt number of bolts to load.
Mounted on side
– Attach bracket and equipment close to a cross member.
It is not permissible to install additional cross members.
Install reinforcement plates on inside of frame web.
Do not introduce force at the centre of the web of the longitudinal member (diaphragm
effect). If this is unavoidable, provide for large surface support on both sides of web.

4.8.2 Chocks
Observe legal regulations and guidelines.
Attachment:
– In suitable mounts so that no rattling noise can heard.
– Secured against loss.
– Easily accessible.
– Removable without danger of injury.

50
4.8.3 Wings and wheelhouses
– Ensure that sufficient distance is present between the tyre and wing or wheelhouse
even with snow or anti-skid chains installed and suspension completely compressed
(even with frame twist). Observe dimension data in offer drawings.
– On chassis with standard holes for mudwing mounts, attach mounts in these holes.

4.8.4 Spare wheel

Mounting:
– According to vehicle drawing below frame, at side of frame or on body.
– Observe legal regulations.
– Easily accessible, simple to operate.
– Double secured against loss.

51
 4.8.5 Rear underride guard
The underride guard installed at the factory conforms with EC guidelines 70/221/EEC.
Modifications are not permissible. If modifications are unavoidable, confer with respon-
sible approval authorities in advance.
In Germany an underride guard is required according to section 32b StVZO when:
– The distance from the end of the vehicle to the last rear axle is greater than
1,000 mm.
– The distance between the road and the chassis or main parts of the body is greater
than 700 mm over the entire width of the vehicle in the unladen state.
Exceptions are semitrailer tractors, working machines and vehicles whose utilisation
would not be possible with an underride guard.
N31.30-0231-20 If an underride guard is required, it must conform to EC guidelines 70/221/EEC.
Install underride guard as far as possible towards the end of the vehicle.
Dimensions:
– Maximum distance from road to underride guard (unladen vehicle): 550 mm.
– Width
Maximum: = width of rear axle (outer edges of tyres).
Minimum: = width of rear axle – 100 mm on each side.
Dimensions based on the widest axle.
– Section height of cross member min. 100 mm.
– Edge radius min. 2.5 mm.

52
Testing strength of underride guard and mount
– With vehicle unladen apply horizontal load to points P1, P2 and P3 in sequence.
Minimum load:
– Point P1 and P3 12.5% of technical gross vehicle weight,
max. 2,500 kg.
– Point P2 50% of technical gross vehicle weight,
max. 10,000 kg.
The distance from the end of the body to the end of the underride guard must not exceed
max. 400 mm at the load points at maximum deformation.
Maximum deformation of original Mercedes-Benz underride guard = 60 mm.

N31.30-0232-22

a = Rear axle width

53
 4.8.6 Side underride guards
– According to EC guideline 89/297/ EEC side underride guards are required for vehi-
cles with a gross weight greater than 3.5 tonnes.
Exceptions are semitrailer tractors, working machines and special vehicles whose
utilisation would not be possible with side underride guards.
– Components such as battery boxes, air tanks, fuel tanks, lamps, reflectors, spare
wheels and tool boxes may be installed in the side underride guard when the speci-
fied distance dimensions are maintained. Brake, air and hydraulic lines and other
parts may not be fastened to the side underride guards.
– The operation and accessibility of all the assemblies present on the vehicle
must not be negatively affected.
– Attach underride guards continuously from front to rear to the greatest extent possi-
ble.
– Adjacent parts may overlap. Overlapping edges must point toward the rear or down-
ward.

54
 1 5 Cab
– Modifications to the cab must not have a negative effect on the operation or clearance
of assemblies and controls or the strength of supporting parts.
– Tilting cabs must not be permanently connected to the body.

2
5.1 Attachments above cab
– Observe the permissible position of the centre of gravity and front axle load.
– Ensure that sufficient free space is present to tilt the cab.

N00.00-2106-20
N00.00-2106-20 5.2 Spoilers
Spoilers on the cab roof may be mounted only at the mounting elements provided for
this purpose. It is not permissible to drill holes in the cab roof to mount spoilers.
Approval by the responsible department is required for other roof attachments (e.g. air
conditioning, sleeper cab).

55
 6 Electrical system
The Atego series uses a new ground concept. The ground circuit for electrical loads does
not run through the vehicle frame (voltage-free frame), this leg of the circuit is formed
by the ground point on the inside of the longitudinal frame member.
Caution! Grounding to the vehicle frame can result in damage to the engine and trans-
mission components.
To prevent damage, if the mounting frame of a body is used for grounding, the mounting
frame should be electrically connected to the ground point on the longitudinal frame
member.

N54.10-0284-20
N54.10-0284-20
6.1 Power supply – auxiliary loads
Vehicles without GGVS approval Observe the following when retrofitting additional electrical equipment:
Grounding for electrical consumers – On request, a 12-volt trailer socket and higher capacity batteries and generators are
(Longitudinal body frame member) available from the factory.
– Before conducting any work on the electrical system: Switch off all electrical consum-
ers and disconnect the negative terminals (–) from the batteries. Only reconnect the
batteries when all disconnected wires have been reconnected.
– Do not connect additional loads to the present fuses already in use.
– Do not connect additional wires to present wires (e.g. with insulation displacement
connectors).
– Provide for adequate fusing of additional equipment by installing additional fuses.
– Current is only to be supplied to 12-volt equipment via a voltage transformer. Current
supply from one battery only is not permissible.
If additional inductances (e.g. solenoid valves) are retrofitted to tractor and trailer vehi-
cles, the freewheel current when switching off must be conducted on a predefined route
to prevent interference being transmitted to other wires by voltage peaks.
N54.10-0285-20
N54.10-0285-20

Ground connection of longitudinal frame

member

56
 For this reason, only solenoid valves with an integrated diode should be used; on hand-
operated switches, the freewheel current must be conducted by a diode.

6.1.1 Electrical consumers up to 10 ampères

The cable connector in the E-box (behind the general module) can be used for the power
supply to retrofitted electrical consumers.
We recommend connecting the consumers in accordance with the wiring diagram (see
page 58). Note the pin allocation in the cable connector.
1

Key to cable connector (pin allocation)

N54.10-0295-20
1 Cable connector in E-box (standard)
N54.10-0295-20 Pin No. Terminal Max. current draw Colour of cable
(Ampère)
1 30 10 rt
2 31 10 br
3 15 2 bl/sw/ws
1 4 4 58 2 gr/ge
5 D+ 2 bl/ge
2 5 6 Reversing lamp 2 ws/rt
3 6

N54.10-1085-20
N54.10-1085-20

Pin allocation in cable connector.

57
 Electrical wiring diagram (current draw up to 10 ampères)
Key
Plug connections
A1/A2 = Module
A31/A32 = Relay
X7 = Plug connector
a = Consumer connector in cab
b = Consumer connector on chassis frame
Wire designations
Example:
N54.00-1084-20 Wire designation 1.5 bl/ge
Wire cross section 1.5 = 1.5 mm 2

Base colour bl = blue

Identifying colour ge = yellow
Wire colours:
bl = blue
br = brown
ge = yellow
gr = grey
or = orange
rt = red
sw = black
ws = white

58
 6.1.2 Electrical consumers over 10 ampères
The fuse box (3) on the longitudinal frame member in the battery box is provided for the
voltage supply to more powerful electrical consumers (see page 60).
Caution! On no account should powerful electrical consumers be supplied from or con-
nected to the general module as the circuitry or the master voltage supply wire
(16 mm2) could be overloaded.
1 2 On hazardous goods (GGVS) vehicles, the ground connections of electrical consumers
(delivery pumps etc.) must be connected to distributor socket supplied for this purpose.
The battery isolator switch (2) and the current limiter for the tachograph, anti-theft
alarm system and electronic switches are also located in the battery box.
N54.10-0306-20
Current supply for additional consumers in the cab or on the chassis frame:
N54.10-0306-20

Connector plate Vehicles without GGVS approval

1 Ground connection (–)
2 Voltage supply (+) – Current supply is only permissible from one connector plate. Note connections.

59
 Vehicles with GGVS approval

2 3

N54.15-0339-28
1 5 4 N54.15-0339-28

1 Switch (GGVS)
2 Battery isolator switch Connecting additional electrical consumers (example)
(GGVS)
3 Distributor socket
ground connections (GGVS)
4 Voltage supply fuse box (+)
5 Fuse

60
 6.2 Electrical wiring
Observe the following points when extending the electrical wiring:
– Use only FLKR wires with the same cross section and same colour code as the stand-
ard wires.
– The wires must be jacketed with an insulating sheath
(with a corrugated sheath for vehicles transporting dangerous goods).
– Attach only original Mercedes-Benz plugs to the end of the wires.
– Connect electrical wires only with junction boxes.
– ABS cables may be extended only with an original Mercedes-Benz wiring harness.

N82.00-0407-20

1 Corrugated sheath (example)

61
 6.3 Installation of lighting
If lighting equipment is covered up by more than 50% when operating moving parts of
the vehicle (e.g. hydraulic tailgate), the vehicle must be suitable safeguarded. An appro-
priate note must be attached at a point easily recognised by the driver of the vehicle.
Vehicles with an overall length of 6 m and registered as of 1.10.94 must be
equipped with side marker lamps according to guideline 91/663/EEC. From this time
on, tie-outs are provided on the wiring harness for connection of the side marker lamps
and suitable tail lamps are installed.
On the ATEGO, the entire lighting system is monitored for the failure of individual bulbs.
If other lights are connected to the existing ones, the current flows are changed and
faults are indicated in the Telligent® maintenance system display.
If additional lights are installed, these should therefore be connected via the pin alloca-
tion of the trailer socket as this is not monitored.

6.4 Anti-theft alarm system

On vehicles with anti-theft alarm system, it is possible to also monitor the body or to con-
nect an external motion sensor. To do this, the existing ground bridge must be separated
from the connector A44.2 in the E-box in accordance with requirements and must be re-
placed with supply wires to the box-type body.

62

N31.10-0332-20
Clearance dimensions
N31.10-0333-20
Clearance dimensions
7 Trailer coupling
– Attachment of the trailer coupling must fulfill all national regulations. In Germany
DIN 74 050 and EC guideline 94/20/EC apply.
– Take clearance dimensions into consideration. In Germany, DIN 74058 and EC guide-
line 94/20/EC.
– In Germany, a certificate of endorsement must be requested from the vehicles section
of the "Berufsgenossenschaft für Fahrzeughaltung" (Professional Society for Fleet
Owners), D-22757 Hamburg (Tel. 0 40/3980-0, Fax 040/3980-1999) in case of devia-
tions from the accident prevention regulations (UW).
– When retrofitting trailer couplings use only brands and models approved by us and
original MB end cross members.
Observe hole pattern in the end cross member for determination of coupling size.
– In exceptional cases (e.g. dump truck bodies) use a trailer coupling with joint allow-
ing vertical movement of the coupling jaw.
– Approval by the responsible department is required for installation of short cou-
plings.
The size of the trailer coupling can be calculated from the D-value.
mk × ma
D = g × ------------------ (kN)
mk + ma
D = Drawbar value
mk = Permissible gross weight of tractor (motor vehicle) in t
ma = Permissible gross weight of trailer in t
g = 9.80665 m/s2
63

N31.10-0334-20
Clearance dimensions
Jaw-type couplings
– Distance from the centre of the coupling pin and trailer coupling to end of body max.
420 mm. Maintain clearances.
– In exceptional cases the distance dimension of 420 mm may be exceeded:
Maximum distance 650 mm on vehicles with tilting bodies or rear mounted equip-
ment.
Maximum distance 1,320 mm, when height from road to bottom edge of body is at
least 1,150 mm.
– Safe and easy operation of the coupling must not be negatively affected.
If one or more regulations regarding safe and easy operation cannot be maintained, use
a coupling with remote control. The remote control must satisfy the following condi-
tions:
– Trouble-free operation.
– The control must be permanently mounted and must not be detachable.
– The control must be easily accessible, simple to handle without danger and mix-ups
must be excluded.
– The trailer coupling must permit safe disengagement even under an axial distortion
of at least + 10°.
– When the trailer is coupled, it must be easily possible to determine by visual inspec-
tion or with an indicator whether the coupling pin is engaged and secured.
Operating instructions must be included with the vehicle indicating the special features
and operation of the coupling. No modifications may be made to the trailer coupling (e.g.
bending, welding or cutting off the hand lever).

N31.10-0335-20

Clearance dimensions

64
7.1 Use of vehicle with centre-axle trailer
A centre-axle trailer is a trailer with one axle or group of axles
– which is connected to the towing vehicle by a drawbar connected rigidly to the trailer
chassis.
– whose gross weight is not supported to a significant extent by the towing vehicle as
a result of its design.
Corresponding to the standard draughts for automatic pin couplings 40 and 50 in DIN
74051 and 74052 only the trailer loads listed in the following table are permissible for
the relevant DIN coupling sizes with centre-axle trailers:
Coupling sizes Permissible trailer load with
centre-axle trailer in kg

G 150 9,500
G5 12,000
G6 18,000

Maintain minimum front axle loads for sufficient steerability according to section 2.11.
The trailer drawbar load must be taken into consideration in the design.

65
 7.2 Lowered trailer coupling
Installing according to illustrations.
Move standard trailer connections, if required.
On these versions the permissible trailer load listed in the vehicle documents remains unchanged.

744

757

7 N31.30-0218-29
N31.30-0218-29

66
744

43

N31.30-0217-29
N31.30-0217-29

67
 Lowered trailer coupling for centre-axle trailers
Equip vehicles with mounting frame with dimensions of 120 × 60 × 6.
This does not apply to interchangeable bodies without an auxiliary subframe.
Fasten longitudinal members and coupling brackets with at least 10 flat-head bolts (M 14 × 1.5).

Graphic 80 x 80 mm Graphic 80 x 80 mm

N31.10-0337-27
N31.10-0336-27

Vehicles without mounting frame

1 Chassis frame 3 Reinforcement 5 Channel
2 Cross member 4 Gusset plate

68
 Graphic 80 x 80 mm Graphic 80 x 80 mm

N31.10-0338-27
N31.10-0339-27
Vehicles with mounting frame
1 Chassis frame 3 Console
2 Mounting frame: 4 Cross member

69
 8 Mounting frame
– A mounting frame or substructure with the function of a mounting frame is required
for all bodies for proper connection between the chassis and body (exception: self-
supporting bodies and mounting frames as floor assembly).
– The longitudinal mounting frame members should be level and contact the upper
cord of the chassis frame following the course of the frame.
Wood strips between the longitudinal chassis frame members and longitudinal
mounting frame members are not permissible.
– Position mounting frame cross members above the chassis frame cross members.
– Use edged U-channels for the longitudinal members or commercially available
U-channels for vehicle construction (not rolled steel channels).
– The dimensions for the longitudinal members can be calculated from the required
moment of resistance (Wx) for the body and the chassis. Please refer to the diagram
on page 74.
The specified moments of resistance and channel dimensions assume that the longi-
tudinal frame members are loaded uniformly on both sides.
If a number of superstructures are installed on one chassis (e.g. platform and hy-
draulic tailgate), the higher specified moments of resistance must be used for the
mounting frame.

70
 8.1 Material quality
Material qualities for specified steel mounting frames:
– Mounting frames mounted with U-bolt or brackets
(friction locking) = St 52 or E 380 TM.
– Mounting frames with rigid mount
(form locking) with butt straps = E 500 TM.
1
Material Tensile strength Yield strength
N/mm2 N/mm2
E 500 TM >560 500

N31.20-2009-20 Mounting frames of high strength steels (e.g. N-A-XTRA) must have at least the rigidity
N31.20-2009-20 of steel mounting frames. The mounts must be friction locking.
1 Mounting frame Aluminium platform superstructures
– Observe instruction of aluminium manufacturer.
– The longitudinal members, plank floor, floor panels and cross members
must form one self-supporting unit.

71
 8.2 Design
The sections should taper slowly at the front ends of the longitudinal members.
Continuous mounting frames are required for:
– Bodies with high centre of gravity
– High point loading
– One-sided loading
– Superstructures above cab
For example for: tilting bodies, glass transport superstructures, towing superstructures,
loading cranes, telescopic masts, hydraulic tailgates, etc.
The longitudinal members should extend as far as possible to the front, and at least be-
yond the rear front spring bracket at the least.
N31.20-0215-20
1 Mounting frame
2 Chassis frame

N31.20-0216-20 N31.20-0217-20

1 Mounting frame 1 Chassis frame

2 Chassis frame 2 Mounting frame

72
 If extremely high longitudinal members are required or to achieve an extremely
low overall frame height, the U-channel can be designed as follows for friction
locking connections
– As a closed box (figure B)
– Inside overlapping (figure C) or
– Overlapping (figure D).
This increases the moment of resistance, but also the torsional rigidity. Ensure good
transition from closed longitudinal member to open U-channel.

N31.20-0218-20

Graphic 112 x 50 mm

N31.20-0219-20 N31.20-0220-20
Transition from closed to A = open U-channel (Wx see diagram of channel dimensions)
open U-channel B = closed U-channel (Wx see diagram of channel dimensions × 1.25 )
C = inside overlapping U-channel (Wx see diagram of channel dimensions × 1.75)
D = overlapping U-channel (Wx see diagram of channel dimensions × 1.9)

73
 8.3 Channel dimensions
Channel dimensions for longitudinal mounting frame members (open channel) [
Mounting frames and chassis frames should have the same material thickness and flange width.
Channel height in mm

260
250
240
70x8
230
70x7
220
210
70x6 65x7
200
190
180
Graphic 170 x 95 mm 65x6

170
160 (29)
150
140
130
120
110
100
90
80
70
60
50

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
N31.20-0202-29
N31.20-0202-29
Wx/cm3

74
8.4 Floor assembly as mounting frame
A mounting frame with continuous longitudinal members is not required when
the floor assembly of the body can assume the function of the mounting frame.

N31.20-0209-22
N31.20-0209-22

75
 8.5 Mounting
Mount as required depending on the chassis model and intended body as well as utili-
sation of the vehicle.
Plan a sufficient number of mounts to take up the forces of braking and cornering.
Proper mounting is decisive for:
– The handling and operational safety of the vehicle.
– The service life of chassis frame and body.
Securing elements (consoles) are available from the factory using code CR4. The loca-
tion of the consoles can be taken from the relevant offer drawing.
For a friction-locking connection, the longitudinal members must be fixed in both longi-
tudinal and lateral directions.
Longitudinal fixation:
– Remove mounting rivets for end cross member.
– Screw mounting frame, chassis frame and end cross member with flat-head bolts
complying with Mercedes-Benz standards 10105, 10112 and 13023.

76
 Lateral fixation:
– Use guide plates of sufficient size.
– A gap should not be present between the guide plates and mounting frame.
With prefabricated mounting frames, take production tolerances for chassis frame
width into consideration (max. +6/–3 mm).
Offset systems
– If the mounting frame is wider than the chassis frame, provide console fixtures.
– The upper side of the console and the chassis frame must be in a single plane.
– Weld the mounting frame and the consoles together.

4
3
2

1 Chassis frame
2 Mounting frame
3 Cross member
4 Bolts for longitudinal fixation
5 Guide plate for lateral fixation 5 1 N31.20-0208-22
N31.20-0208-22

77
 8.5.1 Friction-locking connection – console mounting
– Limited movement of the longitudinal mounting frame member in relation to the lon-
gitudinal chassis member is possible.
– Perform strength calculation separately for each longitudinal member.
– Distribute bending moment in accordance with moments of inertia.
– The first two mounting points should be flexible (cup springs, rubber mounts).
– Use guide plates only on the chassis frame in the area of the rear axles and rear
springs (exception: vehicles with two driven rear axles).

78
On vehicles equipped with standard consoles
mount the body to these consoles.
– Use a rectangular washer to cover the oblong holes between the chassis console and
cup spring
The same applies when T-bolts are used instead of consoles.
– Provide for resilient mounts in the area behind the cab
(e.g. using cup springs or rubber mounts).
– An interval (A) of at least 5 mm must be present between the body and the chassis
console behind the cab and the front of the rear spring brackets after tightening the
bolts. Compensate for different intervals on the other consoles with shims.
– Do not twist mounting frame when tightening bolts.

N31.20-0210-22
N 31.20-0210-22

79
 8.5.2 Form-locking rigid connection – butt strap joint
– Movement of the longitudinal mounting frame member in relation to the longitudinal
chassis member is not possible.
– The longitudinal mounting frame member moves with the longitudinal chassis mem-
ber (bending, twisting).
– Both longitudinal members can be considered as one single member for strength cal-
culation.
– For bodies on cement mixer trucks, bodies with a loading crane at the rear, rear end
tilting dump truck bodies and similar, the body mounting frame must be rigidly at-
tached to the chassis frame.
– The mounting frame must be closed to form a box in the rear area and reinforced with
a diagonal cross.
N31.20-0222-20 – Mount torsionally rigid bodies (e.g. box bodies, tanks) resiliently on the mounting
frame behind the cab. Continuous resilient mounting is not permissible.
– Screw the butt straps to the chassis frame with at least 3 flat-head bolts complying
with Mercedes-Benz standards 10105, 10112 and 13023.
– Maximum distance between butt straps (A) 500 – 700 mm.
– Match material strength of butt straps to forces and weights of body. At least same
strength as chassis frame.
– Use console mounting in the front area.
– Approval by the responsible department is required for continuous butt strap mount-
ing up to the area of the cab (e.g. for mounting heavy loading cranes).

N31.20-0223-20

Butt strap mount

80
 8.5.3 Quick-release lock for interchangeable bodies
– Plan sufficient number of quick-release locks for taking up the braking and cornering
forces.
– Ensure that the design and fastening function is reliable.
– Play must not be present when the body is locked on the mounting frame.

Graphic 112 x 85 mm

N31.20-0224-24

1 Chassis frame
2 Mounting frame
3 Mounting plate
4 Quick release lock
5 Mounting device

81
 9 Types of bodies
9.1 Self-supporting bodies
Self-supporting van or box-type bodies do not require mounting frames with con-
tinuous longitudinal members if the cross members are installed at maximum in-
tervals of 600 mm.
If required the maximum interval of 600 mm may be exceeded in the area of the rear
axle.

mm
.600
m ax

N31.20-0207-24
N31.20-0207-24

82
9.2 Platform, van, box-type and interchangeable bodies
– The body must be mounted with mounting frame (U-channel longitudinal members)
to ensure that the chassis frame is loaded uniformly.
– The body must be in contact with the longitudinal chassis frame members without
distortion.
– Park vehicle on level, horizontal surface to install body.
– If loads are concentrated at points or small areas on the standard
platform (e.g. transport of cable drums, coils, etc.) reinforce substructure and plat-
form as required to support the load.
– Before mounting body: weigh chassis and establish body length.
– Chassis with long cab:
– If necessary, shorten frame overhang at rear so that permissible rear axle load is not
exceeded and minimum front axle load is achieved.
– Attach reflectors to body according to legal regulations (in Germany Sec. 51a StVZO).
– Attach an air deflector behind the cab to prevent hot engine air from coming into con-
tact with the body.

83
 Platform superstructure
Moment of resistance of mounting frame longitudinal member

Vehicle Moment of resistance

per longitudinal member in cm3
ATEGO 45
For channel dimensions of longitudinal members, see diagram on page 74.

Interchangeable bodies
Twist locks
– Secure extension arm to chassis frame with at least 6 bolts M 14. Use pressure dis-
tribution plates to ensure that forces exerted are widely spread. If possible, use the
existing holes on the chassis frame.

9.3 Loading cranes

The crane size must be matched to the chassis size.
Ensure that the vehicle is stable when standing. Limit slewing range of crane as re-
quired.
In Germany, loading cranes mounted on vehicles must meet the accident prevention
regulations (UVV).

84
9.3.1 Loading crane mounted behind cab
The loading crane and supporting devices must not have a negative effect on the opera-
tion of other components.
Mount loading crane on steel mounting frame.
Mounting frames
– The longitudinal mounting frame members should extend to below the cab. On vehi-
cles with long cab extend mounting frame up to the rear of front spring support or
limit slewing range of loading crane.
– Design longitudinal mounting frame members as box in area of loading crane.
The transition from box to U-channels should be gradual and adapted to the load.
– If a crane is to be mounted with four support points, the authorisation of the respon-
sible department is required.
– For maximum crane loading moment (kN × l), see page 89.
– For moments of resistance (Wx) of longitudinal mounting frame members, see
page 89.
– These values apply to longitudinal chassis frame and mounting frame members with
equal loads on both sides. Approval from the responsible department is required for
crane pillars which are not centred.
– For profile dimensions of mounting frame longitudinal member, see page 74.
The dimensions for the longitudinal mounting frame members in the area of the plat-
form or dump truck bodies are given in the table for platform bodies and dump truck
bodies.
– The mounting frame can be fastened according to section 8.5. If this is not possible,
connect mounting frame rigidly to chassis frame and mount loading crane resiliently.
– Approval from the responsible department is required when the crane bracket is fas-
tened at three points.
– Provide outriggers for each loading crane. We recommend hydraulic outriggers.

85
 – Do not lift vehicle with outriggers (frame damage).
– Mark outriggers extending beyond the vehicle during stationary operation with con-
spicuous colours, reflectors and warning lights.
– Calculate the platform length according to the position and weight of the loading
crane in compliance with permissible axle loads.
– If the maximum crane load moments are exceeded, approval is required from the re-
sponsible department.
The crane mount must be reinforced.
Use vehicle only on level, paved roads.
– The resulting load distribution may make extension of the frame necessary.

140 x 60 mm

N31.20-2008-28
N31.20-2008-28

86
 Actual dimension
110 x 57 mm
112 x 50 mm (???)

N31.20-2013-22

Actual dimension
110 x 57 mm
112 x 50 mm (???)
Loading crane mounting
1 Chassis frame
2 Mounting frame
3 Crane base
4 U-bolt
5 Console
6 Mounting plate N31.20-0226-22

87
 5 3 5
3

2
2

1 4 N31.20-0206-29
N31.20-0206-29

88
Moments of resistance for loading crane attachment

Diagram/Graphic

170 x 95 mm

N31.20-2012-29

89
 9.3.2 Rear-mounted loading crane
– Operation with centre-axle trailer is not permissible.
– The legally prescribed headlamp height must be maintained when the front axle is
unloaded.
– Due to the concentrated loads occurring with the loading crane, reinforcement of the
chassis frame with a steel mounting frame is required. See diagram on page 94 for
crane load moments (kNm) and mounting frame moments of resistance (Wx).
– For channel dimensions of longitudinal members, see diagram on page 74.
– These values apply to longitudinal chassis frame and mounting frame members with
equal loads on both sides. Approval from the responsible department is required for
crane pillars which are not centred.
– If possible extend the mounting frame to below the cab and lay out as box from the
end of the frame to the front of the rear spring bracket.
– The transition from the box section to U-channel should be gradual.
– Connect mounting frame rigidly to the chassis frame (e.g. with butt straps).
– Provide for diagonal braces in the rear area of the mounting frame.
– The length of the diagonal braces should be at least 1.5 × frame width.
This increases the torsional rigidity of the chassis frame.
– If a diagonal brace is not possible, e.g. in the area of the shock absorbers or spring
loaded brake cylinders, inclined braces or tubular cross members can be installed.
– Equip chassis with heavy-duty rear springs and stabilizer on rear axle if necessary.
– Do not exceed permissible rear axle load. Observe minimum front axle load. The
vehicle stability must be ensured by a sufficient number of outriggers.
– Do not lift the vehicle with outriggers (damage to frame)!
– Mark outriggers extending beyond the vehicle in stationary operation with conspicuous
colours, reflectors and warning lights.

90
 1

1 Chassis frame 7
2 Mounting frame
3 U-channel cross member
4 Diagonal reinforcement
5 Middle of 1st rear axle
6 Middle of rear axles N31.20-0203-24
7 Middle of 2nd rear axle N31.20-0203-24

91
 4 5
4 5

3
2

1 1

N31.20-0205-29
N31.20-0205-29

1 Chassis frame 3 Reinforcement 5 Cross member

2 Mounting frame 4 Diagonal reinforcement

92
 1 2

1000

1000

N31.20-0204-24
N31.20-0204-24

Tubular cross member 2 Mounting frame 4 Chassis frame

1 Tube (min. 80×4 mm) 3 Mounting bracket

93
 ATEGO: Crane load moments and mounting frame moments of resistance – rear-mounted loading crane

1)
1)
Diagram/Graphic

170 x 95 mm

N31.20-0234-29

A = Two-axle vehicles (4×2)

B = Three-axle vehicles (6×2)
C = Three-axle vehicles (6×4)
1) Material thickness of longitudinal chassis frame member 7 mm

94
 9.3.3 Removable loading crane
– Installation can be accomplished according to section "Rear-mounted loading crane".
– Ensure that lighting meets legal regulations.
– Operation of centre-axle trailers is not permissible.
– Ensure good access to trailer, brake and light connections. If necessary provide
adapter for second coupling.

9.3.4 Vehicles with lifting trailing axle (lifting axle)

– Do not exceed permissible axle loads (even with trailing axle lifted).
– Observe minimum front axle load (even with trailing axle lifted).
– When handing over the vehicle the vehicle owner must be advised that the lifting
N31.30-0233-20 axle must not be raised when a loading crane is mounted on the rear of the vehicle.
Removable loading crane

95
 9.4 Dump truck bodies
Due the extraordinary loads dump truck bodies capable of tilting in three directions or
to the rear may be installed only on the chassis intended for this purpose.
If required and available, install reinforced rear springs and stabilizers.
Articulated bearings:
– On 3-way and rear dump truck bodies, position the rear articulated bearing as close
as possible to the rear axle.
– The lowered tailgate must not strike the end of the frame, the lighting equipment or
the trailer towing hitch
– Provide guide brackets for the front articulated bearings to guide the articulated bear-
ings when the platform is lowered.
Safety precautions:
– The arrester cables should hang slightly in the end position
– Install a support (folding support) to prevent the platform from dropping
– Safeguard the control elements against unintentional operation
– The "Platform" indicator lamp should be connected to give a warning when the plat-
form is not completely tilted back (driving position).
Tilting press:
– If possible, align the mounting frame and chassis frame cross members with each
other
– Three-way dump truck bodies:
The centre of pressure of the tilting press must be in front of the centre of gravity of
the body and payload.

96
Mounting frame:
– The mounting frame must be manufactured of steel, without joints and with suffi-
ciently large cross members.
– Close the rear area to the box and brace with a diagonal cross.
– Connect the mounting frame to the chassis frame in accordance with the load, as de-
scribed in section 8.5.1.
– Weld guide plates to the mounting frame in the area of the cross members for lateral
fixation of the mounting frame.
Channel dimensions and mounting frame moments of resistance:
The values given refer to standard operational conditions. Confer with responsible de-
partment for arduous operating conditions.
Vehicle Moment of resistance (Wx)
per long. member in cm3
ATEGO 2-axle 60 1) 2)
3-axle 90 3)

1) Closed as a box above the rear axles

2) Securing the mounting frame rigidly to the chassis frame. In the
area of the rear articulated bearing,
with 4 flat-head bolts M 14 × 1.5 on each side.
3)
Mounting frame closed as box from the end of the frame to approximately 2,000 mm in front of the
middle of the rear axles. Securing the mounting frame rigidly to the chassis frame. In the area of the
rear articulated bearing, with 4 flat-head bolts M 14 × 1.5 on each side.
For channel dimensions of longitudinal members, see diagram on page 74.
Three-way and rearward tippers are not permissible on vehicles with disc brakes on the
rear axle. The brake system could be damaged by ingress of particles of bulk material.
Roll-off and removable dump truck bodies are permissible.

97
 9.4.1 Special tilting bodies on standard chassis
Under certain conditions standard chassis can be used for special tilting bodies such as
cement silos and dump truck bodies tilting in three directions or to the rear only.
Semitrailer tractor chassis may not be used.
– Vehicle operation on metalled roads only, not on construction sites.
– To reduce the danger of the vehicle tipping, limit the tilting angle of the body to the
rear to 35°. For this reason, only transport loads which can slide out easily. Fit the
dump truck body with a tilt stabiliser and secure it precisely above the rear axle or
the middle of the double axle.
– The length of the body should not exceed 5,500 mm on two-axle vehicles, and
6,500 mm on three-axle vehicles.
– Shape the mounting frame from the end of the frame to the tilting press as a box chan-
nel and stiffen it with a diagonal cross.
For channel dimensions of longitudinal members, see table.
– The mounting frame must be rigidly fixed to the chassis frame.
– Locate the rear articulated bearing as close as possible to the rear axle.
– If the frame is shortened, always install end cross members. On two-axle vehicles, the
spring cross member can be replaced by the end cross member.

98
– Equip the vehicle with heavy-duty springs and stabilisers on the rear axle (if availa-
ble from the factory). The trailing axle must not be raised during tipping.
– Vehicles with air-sprung rear axle must be lowered to the basic position of the air
spring (lower end position) for loading and unloading. An easily recognised sign to
this effect should be attached to the body, included in the operating instructions and
attached to a place within the range of view of the driver.
– Three-way and rearward tippers are not permissible on vehicles with disc brakes on
the rear axle. The brake system could be damaged by ingress of particles of bulk ma-
terial. Roll-off and removable dump truck bodies are permissible.
– Dump truck bodies are not permissible on vehicles with disc brakes on the rear axle.

Mounting frame moments of resistance – special tilting bodies

Vehicle Moment of resistance (Wx)
per long. member in cm3
ATEGO 2-axle 70
3-axle 90

For channel dimensions of longitudinal members, see diagram on page 74.

99
 9.5 Tank and dry bulk bodies
– Observe permissible centre of gravity heights.
– Tank and dry bulk bodies must be equipped with a continuous steel mounting frame.
Minimum quality E 380 TM.

N31.20-0227-20
Actual dimension
Four-point mount at front
110 x 80 mm (24) (???)

N31.20-0229-24
Rigid mount at rear 2 Mounting frame 4 Console
N31.20-0228-20 1 Chassis frame 3 Resilient mount 5 Intermediate block

Three-point mount at front

100
– Ensure that the torsional stability of the chassis frame is not negatively affected by
the connection between the body and the mounting frame or between the chassis
frame and the mounting frame.
– Locate tank and dry bulk body mounts as close to the spring brackets as possible.
– Locate rigid mounts at the rear to ensure safe handling characteristics.
– Do not exceed distance dimensions specified in table from centre of rear axle to body
mount. Locate front body mounts as close as possible behind the cab.

Mounting frame moments of resistance and body mount spacing

Vehicle Max. distance Steel mounting frame
from centre of rear axle 1) moment of resistance (Wx)
to body mount per longitudinal member
behind rear axle (mm) min. cm3

ATEGO 2-axle 1,200 70

3-axle 1,000 70
1)
Centre of rear axles on three-axle vehicles.
For channel dimensions of longitudinal members, see diagram on page 74.
– When goods with different specific weights are transported:
Mark filling level on tank or reservoir so that the permissible filling quantity is visi-
ble.
It is also possible to attach a load indicator with acoustic or optical warning device in
the cab to the rear axle in addition.
– On tank and dry bulk bodies with separate compartment:
The loading and unloading plans must be attached to the vehicle where they are eas-
ily visible.
It must be ensured that the permissible axle loads are not exceeded and the specified
minimum front axle load is achieved under all loading conditions.
– We recommend the vehicle be equipped with the Telligent® roll control system wher-
ever this is available.

101
 9.5.1 Tank and dry bulk bodies without continuous mounting frame
– Equip vehicle with heavy-duty springs and stabilisers.
– Observe permissible centre of gravity heights.
– Confer with responsible department before modifying wheelbase.
– The mounting frame section must extend beyond the front and rear of the rear spring
brackets (pneumatic suspension supports) on two-axle vehicles for sufficient transfer
of force.
– Provide a base of min. 1,000 mm for the front mounting frame section.
– Both sections should be designed as an edge profile (minimum dimensions
100 × 70 × 6) with web plate and smooth transition.
– Direct attachment of tank without mounting frame sections is not permissible.
– The tank must be mounted rigidly at the rear and resiliently at the front.
If vehicle vibrations are present following attachment, a mounting frame with appropri-
ate mounting is required.

9.5.2 Platform-mounted tanks

– Mount and remove platform-mounted tanks only in empty state.
– A vehicle model homologation and (in Germany) a test certificate according to
section 6 paragraphs 1 and 2 of the regulations for road transport of hazardous sub-
stances (GGVS) are required for transport of dangerous goods.
– If a platform-mounted tank is mounted on a platform truck or dump truck, the plat-
form-mounted tank must be connected to the chassis frame using friction locking
connections.
Provide two mounting points in the area of the rear axle.
On dump trucks the tilting mechanism must also be secured against tilting.

102
9.6 Vehicles for transport of hazardous goods
The applicable safety regulations must be observed. Conversion of the chassis re-
quires written approval from the responsible department. Include applicable draw-
ings with all dimensions and weight data in triplicate with application.

Safety regulations
– For national approval in Germany:
Regulations for Road Transport of Hazardous Substances (GGVS).
Guidelines on implementation, e.g. Guidelines to Regulations for Road Transport of
Hazardous Substances (TRS 003), must be observed.
– For international transport:
European Agreement on International Transport of Hazardous Substances on the
Road (ADR).
It is assumed that the body manufacturer is familiar with these regulations.

Transport of combustible substances, classes 2 and 3

With tanks or carrier vehicles with
– platform-mounted tanks
– vessel batteries
– tank container with capacity greater than 3,000 litres
the following regulations must be observed particularly:
1. Electrical equipment – Rnn 220 512 to 220 516
2. Brake system – Rnn 220 521 and 220 522 –
Vehicles for transport of hazardous goods should always be equipped with ABS – re-
gardless of the gross vehicle weight
3. Fire protection – Rnn 220 533 to 220 536

103
 For vehicles registered in Germany, the equipment required for the basic vehicle can be
supplied from the factory with the appropriate approval. For vehicles registered outside
Germany the technical solutions for the specific country are necessary.

9.7 Vehicles for transport of aggressive substances

On vehicles for transport of chemically aggressive substances all compressed air lines,
brake lines, brake hoses and electrical wiring must be protected against the influence
of chemicals by the body manufacturer.

9.8 Truck-mounted cement mixers

Truck-mounted cement mixers may only be mounted on chassis approved for this
purpose.

9.9 Winter road service vehicles

Snow plough
– Mount attachment plate for snow plough according to mounting instructions of snow
plough manufacturer. The mounting instructions must be approved by Daimler-Benz AG.
– Observe maximum permissible front axle load.
– Access to the front windshield for cleaning as well as actuation and use of the front
towing coupling must be possible.

104
9.10 Roll-off and removable dump truck bodies
These guidelines apply similarly for roll-off and removable dump truck bodies.
– The front axle must not lift when mounting or removing the container (possible dam-
age to frame).
– Attach supports at end of vehicle.
– The stability of the vehicle must be ensured during the loading and unloading proce-
dures.
– Observe permissible centre of gravity heights.

9.11 Other bodies

These guidelines apply by analogy to other special bodies such as refuse collection
trucks, municipal vehicles or fire fighting vehicles.

105
 10 Loading tailgates
When installing loading tailgates observe the following:
– Calculate load distribution. Take all special equipment into consideration.
– Shorten body length and rear chassis overhang, if necessary.
– The permissible rear axle load must not be exceeded.
– Observe minimum front axle load.
– Vehicles with extended frame overhang are suited for attachment of a hydraulic
tailgate only with certain restrictions. Ensure that the points specified above
are observed.
– On vehicles with steel springs, reinforced rear springs are required
– In Germany, loading tailgates must conform with the accident prevention regulations
(UVV).
– Check stability when stationary.
– Extend mounting frame as far to the front as possible and connect rigidly to the chas-
sis frame, from the end of the frame up to the front of the front bracket for the rear
spring.
– We recommend using only hydraulic support devices (outriggers). Do not lift vehicle
with outriggers (possible damage to frame)!

106
– If loading tailgates are installed which have a load-bearing capacity of up to 20 kN,
our requirement for supports can be disregarded, provided:
a) the loading tailgate or body manufacturer gives warning of the potential danger of
operating a tailgate without a support in his assembly or operating instructions;
b) an easily recognised warning to this effect is attached to the loading tailgate. The
body manufacturer is responsible for ensuring that this requirement is satisfied.
– When installing electro-hydraulic tailgates, provide for heavy-duty atternator and
batteries.

Mounting without mounting frame

If a mounting frame is not required according to the table, mount the hydraulic tailgate
to the longitudinal frame members. This layout is based on the use of E 500 TM as the
material for the mounting frame. If a material with lower strength is used, e. g.
E 380 TM, correspondingly higher moments of resistance are required. Approval is re-
quired from the responsible department.

107
 112 x 50 mm

N31.20-0231-22
Mounting with mounting frame

112 x 50 mm

N31.20-0230-22

Mounting without mounting frame

108
Tailgate table
Vehicle Wheelbase Lifting capacity Mounting frame Outriggers
mm up to moment of resistance/
kN longitudinal member
min. cm3
18 t 4x2 3,900 – 5,700 10 1)
-
3,900 – 5,700 15 1)
-
1)
3,900 – 5,700 20 -
1)
3,900 – 4,800 30 x
5,100 – 5,700 30 40 x
18 t 4x2 4,200 – 6,300 10 1)
-
Frame 4,200 – 5,400 15 1)
-
overhang 5,700 – 6,300 15 40 -
1)
extended 4,200 – 4,500 20 -
Code CR2 4,800 – 6,300 20 40 -
4,200 – 4,500 30 40 x
4,800 – 5,400 30 60 x
5,700 – 6,300 30 80 x
18 t L 4x2 3,900 – 5,700 10 1)
-
3,900 – 5,700 15 1)
-
1)
3,900 – 4,800 20 -
5,100 – 5,700 20 40 -
3,900 – 4,200 30 1)
x
4,500 – 4,800 30 40 x
5,100 30 60 x
5,400 – 5,700 30 80 x
1)
x required Mounting frame not required

109
 Vehicle Wheelbase Lifting capacity Mounting frame Outriggers
mm up to moment of resistance/
kN longitudinal member
min. cm3
1)
18 t L 4x2 4,500 – 6,300 10 -
1)
Frame 4,500 15 -
overhang 4,800 – 6,300 15 40 -
extended 4,500 – 4,800 20 40 -
Code CR2 5,100 – 5,400 20 60 -
5,700 – 6,300 20 80 -
4,500 30 60 x
4,800 30 80 x
5,100 – 6,300 30 100 x
20 t 4x2 4,500 – 5,400 10 1)
-
4,500 – 5,400 15 1)
-
1)
4,500 – 5,400 20 -
1)
4,500 30 x
4,800 – 5,400 30 40 x
25 t L 6x2 4,200 – 5,100 10 1)
-
4,200 – 5,100 15 1)
-
1)
4,200 – 4,500 20 -
4,800 – 5,100 20 40 -
4,200 – 4,500 30 40 x
4,800 – 5,100 30 80 x
1)
x required Mounting frame not required

110
11 Semitrailer tractors
11.1 Chassis
– Use only approved semitrailer tractor chassis. The frame, suspension and brake
systems are designed accordingly.
– It is only permissible to attach one semitrailer coupling to a semitrailer tractor chas-
sis. Exceptions must be coordinated with the responsible department.
Semitrailer coupling
– Mount semitrailer coupling so that the rocker pin centre coincides with the semitrail-
er coupling point.
– Determine chassis weight by weighing to calculate the distance between the rear axle
centre and semitrailer coupling point. Comply with permissible weights, particularly
permissible axle loads.
Mudwing
– Attach the wings so that the top of the wing is lower than the contact surface of the
semitrailer coupling.
– Maintain minimum clearance between top frame edge and top of wing. See offer
drawings for dimensions.

11.2 Semitrailers
– The manufacturer of the semitrailer is responsible for compliance with the regula-
tions when the semitrailer truck is driven in the curb-to-curb circle (in Germany, for
example, Sec. 32 StVZO BO-Kraftkreis).
– Check the front and rear slewing radius on the semitrailer as well as the vertical pivot
range.
– Observe minimum height of semitrailer coupling according to ISO standard 1726, if
required.
– Observe clearance for gearshift linkage and above tank filler neck.
Semitrailers with pneumatic suspension should not exceed an inclination of 3° to 4° at
a lateral acceleration of 0.3 g so that the semitrailer tractor does not have to assume the
entire force of the lateral inclination of the semitrailer.

111
 11.3 Connections for brake system and electrical system
– Ensure that connecting lines do not chafe on body components. If there is insufficient
space/clearance to the cab rear panel (e.g. for EURO semitrailers), position coupling
heads higher in accordance with ISO standard 1728 or attach swivelling arm. The
connection lines must not catch on the semitrailer or exert a side pull on the trailer
socket.
The connection lines must be fastened properly when driving without a semitrailer.
– Use only automatic coupling heads on supply pressure and brake lines.
Caution! The excess test connections (with white protective cap) are approved only
for transfer.
– Design bracket for trailer socket so that it cannot bend if a plug should bind.
– Position shield so that the propeller shaft universal joint is covered on the top. This
prevents the cab and semitrailer being soiled by grease.
– If the lines for brake system and electrical system cannot be connected from the road
surface, a suitable working platform with dimensions of at least 400 mm × 500 mm
as well as safe steps to the platform must be provided.

112
11.4 Semitrailer tractor chassis
– Semitrailer tractors are delivered with mounting brackets on the outside.
– The semitrailer coupling plate must be attached directly to these brackets.
– The holes for attaching the semitrailer coupling are present in the centre of the
mounting bracket flange in a 100 mm grid. If retrofitted, these holes must be located
in the centre of the flange of the reinforcement bracket, the interval dimension is
860 mm.
– Ensure that trailing arms and spring loaded brake cylinders have sufficient clearance
at maximum spring compression. If necessary provide for openings in the mounting
plate in the area of the trailing arms.
– Maintain specified dimensions when fastening the brackets.
– Never drill holes in the upper cord of the subframe to fasten the semitrailer coupling
or mounting plate.
– Screw semitrailer coupling and mounting bracket to mounting plates.
– On two-axle vehicles used on construction sites the attachment height for semitrailer
coupling with mounting plate should not exceed 300 mm.
– If it is necessary to raise the semitrailer coupling, use additional mounting frame.
If this is not possible, confer with the responsible department.
The following information is required: vehicle model, model designation,
type of use (e.g. long-haul transport, construction site), type of semitrailer.

113
 – The minimum bolt size for attaching the mounting plate is
M 20 × 1.5–10.9. Use flat-head bolts and nuts according to Mercedes-Benz standards
10105, 10112 and 13023.
Observe tightening torque of 500 Nm during assembly and check during first main-
tenance service.

112 x 85 mm

N31.10-0340-24

114
– On auxiliary frames with cross members the mounting plate must also be bolted to
the cross members. If this is not possible, additional bolts must be provided for con-
necting the mounting plate to the mounting brackets.
– The permissible semitrailer coupling load can only be determined after the coupling
has been mounted.

112 x 85 mm

N31.10-0341-24

115
 11.5 Semitrailer tractor with standard chassis
Standard chassis can be converted to semitrailer tractors only in exceptional cases.

11.5.1 Necessary chassis frame conversion measures

– Shorten the rear chassis overhang to the minimum and replace rear spring bracket
cross member with end cross member.
– Replace standard rear springs with springs for semitrailer tractors.
– Install stabiliser on rear axle.
– Move coupling heads for brake lines and trailer socket to behind the cab.

11.5.2 Mounting frame and semitrailer coupling

Mounting frame dimensions: 100 × 70 × 7 mm
– The mounting frame must have at least two cross members in the area of the semi-
trailer coupling. Extend the longitudinal mounting frame members as far as possible
to the front.
– Fasten longitudinal members rigidly to the chassis frame in the area of the semitrail-
er coupling (with butt straps). Use U-bolts or standard brackets for all other mounts.
– Provide bolts at the end of the longitudinal frame member for longitudinal fixation of
the mounting frame. For this purpose use the mounting holes already present in the
end cross member. Insert bolts into the free bolt holes in the end cross member.

116
 – Attach semitrailer coupling on mounting plate or sectional plate with mounting
brackets.
Ensure that trailing arms and spring loaded brake cylinders have sufficient clearance
at maximum spring compression. If necessary, provide recesses in the mounting
plate.
– Position the end of the reinforcement bracket at least 150 mm in front of or behind
the semitrailer coupling plate.

112 x 85 mm

1 Chassis frame
2 Mounting frame
3 Sectional plate/mounting plate N31.20-0232-24
4 Mounting bracket

117
 12 Programmable special module (PSM)
The interaction of the various control units on the ATEGO is referred to collectively by
the term integrated electronic system (IES).
The individual components are no longer connected by wires in on analogue system;
they are connected digitally with the aid of a high-speed controller area network (HS-
CAN bus).
All integrated control units understand the messages transmitted via the CAN bus and
are adapted to the CAN language, the so-called protocol.
The programmable special module (PSM) was developed to provide body manufacturers
with access to the individual CAN bus data. This special module is available with
Code ED5. This special module can read data from the HS-CAN messages and translate
this into switching signals to the output provided ("high" or "low") or to PWM (pulse
width modulation) signals which can be used by any electronic circuitry in the body.
The PSM presents a clearly defined, EMC-tested interface between the vehicle and the
body, and is capable of diagnosis. It is no longer permissible to modify the vehicle wiring
as this can lead to fault messages from the other control units through the CAN bus.

118
Special customer requirements may be special inputs such as external engine start and
stop or special outputs such as pulse width modulated engine speed and CAN bus com-
patible control modules in the body or trailer.
The PSM module is connected to the IES system by the HS-CAN bus so that it has access
to all messages transferred by the connected control modules. In contrast to this, indi-
vidual signals can be monitored or generated at analogue and digital inputs and outputs.
Example:
1) The RPM is transferred to the drive control (FR) in the form of a message and can be
read by the PSM module. The PSM control module converts the RPM information into
a PWM signal which is then available at an output.
2) In the opposite direction the PSM can convert the position of a manual throttle sender
into an HS-CAN message and use it to set the desired RPM.

119
1. Power supply
from vehicle electrical system
2. High-speed CAN interface
to vehicle junction point
3. Power take-off switch
4. LS-CAN interface
to electronic circuitry in body
5. LS-CAN interface to trailer
6. Digital outputs (relay drivers), e.g. D+
switched
7. Pulse position modulation (PPM) and
Pulse width modulation (PWM) outputs,
e.g. speed signal
8. Digital inputs, e.g. engine start
9. Analogue inputs, e.g. manual throttle
sender
The various PSM interfaces can be sudivided into the following categories (see PSM
block diagram):
In detail the following functions can be realised:
– Engine start/Engine stop
– Engine speed governor (PTOs)
– Reverse gear lock and speed limiter
– Retarder without CAN interface
– Automatic transmission without CAN interface
The inputs are assigned to certain basic functions which can be supplemented with ad-
ditional functions or changed to other functions by reprogramming. The PSM parame-
ters can be reprogrammed with the Mercedes-Benz hand-held tester (HHT).
KL.30
KL.15
KL.31
2 3

A22

HS-CAN
1

PWM PPM LS-CAN LS-CAN

9 5 4
8 7 6 N54.61-0201-28

120
The many capabilities of the PSM cannot be completely described within the scope of
these directives. For this reason a manual has been completed on programming the pa-
rameters, which can be obtained for a token fee by quoting order number 6517 1202 00
to the following addresses:
– For vehicles in use in Germany:
Daimler-Benz AG,
HPC R803 (in-house post code)
Department VSE/ IS
70546 Stuttgart
Fax +49 - 7 11/17 - 8 34 51
– For vehicles in use outside Germany:
Order from the local Mercedes-Benz General Distributor
or General Agent

121
 13 Power take-offs
Types of power take-offs available from the factory
– Transmission-dependent PTOs
– PTOs at front of engine
– PTOs at rear of engine
In case of retrofitting power take-offs, please observe the following:
– After installing the power take-off, fill the transmission with oil up to the lower edge
of the filler opening.
– Allow engine to run for approx. 2 minutes and switch on the PTO.
– Check oil level again and correct as necessary.
Caution:
Failure to observe these instructions could result in damage to the transmission.
Installation of a non-MB PTO must be approved by the responsible department.
Directives on the design and attachment of PTOs made by other companies are available
on request. The use of unsuitable power take-offs may affect the operational reliability
of the transmission.
– The PTO version and transmission ratio depend on the output and speed of the equip-
ment driven.

122
– Transmission-dependent PTOs may only be switched on and off with the vehicle stan-
ding still. These are designed for permanent operation.
– Data on the maximum transferable torque (Nm) for the individual PTOs are guide va-
lues for operation without shock and vibration.
The data is based on a highly durable gearing design and a calculated service life of
at least 800 hours at maximum output, in accordance with DIN 622. Inertia forces
from the equipment to be driven have not been taken into consideration.
– Select the transmission ratio of the PTO so that a minimum (engine) speed of 900 rpm
is maintained with the PTO under load.
The PTO should operate in the maximum torque engine speed range.
– Exposed propeller shafts, fans or pulleys must be covered.
– No belts or chain drives should be attached to the output shaft or flange of the PTO.
When absolutely necessary in special cases submit drawings and required data for
approval.

123
 13.1 Transmission-dependent PTOs
– The PTO is driven from the transmission idler shaft.
– Versions:
One or two drives.
Various directions of rotation.
Drive with flange for propeller shaft.
Direct attachment of hydraulic pump.
Shift lockout for transmission.
With or without coupling flange.
The installation guidelines for PTOs (part number 650 584 00 00, order
number 6550 6496 71) contain all important data such as :
– Output possibilities
N26.45-0210-20 – Output speed
Transmission-dependent PTO
– Continuous output
Double drive
– Transferable torque
– Direction of rotation and installation dimensions
– Dimensions of coupling flange
This information is also available through MB-AS (see page 8).

The permissible PTO capacity can be calculated according to the following formula:

M×n×i
P = ---------------------
9,550
P = Permissible PTO output (kW)
M = Permissible output torque (Nm)
n = Engine speed
i = PTO transmission ratio

124
 – For engaging and disengaging the power take-off, refer to vehicle operating instruc-
tions.
– Operation while driving is only possible to a limited extent and always requires our
approval.
– The PTO is connected to the manual transmission oil circuit.
– If a hydraulic pump is installed directly, note the maximum permissible moment of
inertia
The maximum moment of inertia must not exceed the following values:
Code PTO Max. moment Position
N05 NA 121 - 2 c 25 Nm below
NB3 NA 123 - 10 c 40 Nm below
NB7, NB8, NB9 NA 123 - 11 b/c 25 Nm inside
N55.30-2003-20 NC0, NC1, NC2 NA 125 - 11 b/2c 25 Nm below
NC3 NA 125 - 11 c/2c 40 Nm above
ND3 NA 124 - 10 c 40 Nm above
M = Moment of inertia (Nm)
ND7, ND8, ND9 NA 124 - 11 b/c 25 Nm below
G = Weight of pump, including
fittings NR8 NA 125 - 11 b/c/R 40 Nm above
s = Distance between centre of gravity of
pump and pump flange area NL8 NA 60 - 2c 25 Nm

NN2 NA 60 - 2c 25 Nm

NR5 NA 125 - 10c/R 40 Nm

Caution!
Exceeding these moments of inertia can cause damage to the PTO or to the trans-
mission.

125
 13.2 Dump truck pump
The Meiller axial dump truck pump installed as a standard feature on dump trucks is
also available for other chassis as special equipment.
Two versions of PTO are available for dump truck pumps:
Version "b" with flange for drive via propeller shaft.
Version "c" with splined shaft for direct connection.
The driving capacity (required torque at PTO) can be calculated according to the follo-
wing formula.
9,550 × P
M = ---------------------------
n×η
N26.45-0212-20
Dump truck pump
when delivery rate is known
15.9 × Q × P
M = ---------------------------
n×η
M = Torque (Nm)
n = rpm
P = Power (kW)
Q = Delivery rate (litres/min)
η = Efficiency

126
The pump capacity can be calculated according to the following formula:
Q×p
P= --------------------
600 × η
P = Power (kW)
p = Pressure (bar)
Q = Delivery rate (litres/min)
η = Efficiency

When installing other hydraulic pumps observe:

– Safety clearance to other equipment and chassis parts (propeller shafts, cross mem-
bers).
– Static and dynamic load on pump.
– Note maximum permissible moment of inertia of the hydraulic pump
(see page 125).
– Vibration characteristics of engine suspension,
provide for separate suspension on chassis frame if required.

127
 13.3 Power take-offs at front of engine
Auxiliary equipment (e.g. compressors, hydraulic pumps, fire extinguishing pumps
etc.) can be driven by a PTO from the crankshaft. PTOs using either propeller shaft or
belt drive are possible, depending on the type of vehicle and output required. If the en-
gine has noise encapsulation, provide opening for drive.
Belt drive
– The transferable power is limited (approx. 25 kW).
If higher power is required, confer with responsible department.
The following data is required: Transmission ratio, rpm, number of belts, belt length,
operating time and equipment to be driven.
– A hydraulic pump is available from the factory.
– Performance data Single hydraulic pump
Delivery rate: 16 cm3/rev
Operating pressure: 170 bar
Max. speed: 2600 rpm
Drive: Poly-V-belt
– Performance data for tandem hydraulic pump:
Circuit 1 Circuit 2
Delivery rate: 14 cm3/rev 5.5 cm3/rev
Operating pressure: 250 bar 250 bar
Max. speed: 3,000 rpm 3,000 rpm
Propeller shaft drive
– The crankshaft end play must not be affected by attachment of a propeller shaft.
– Approval is required from the responsible department.

128
13.4 Power take-offs at rear of engine
On the ATEGO series, a PTO installed at the rear of the engine is available from the fac-
tory. The engine-driven PTO cannot be switched on and off.
Direction of rotation is the same as that of the engine.
Transmission ratio: 1.071 × engine speed.
– Approval is required from the responsible department for retrofitting equipment.
– Do not exceed maximum permissible torque.
Provide for overload protection (e.g. pressure limitation for hydraulic pumps, for
other equipment overload clutch, lock-up protection or breakage protection).
Maximum Briefly permissible Maximum moment Part number
transferable excess torque of inertia of resilient
torque (e.g. starting up (resilient coupling) coupling
Nm and shifting) in kgm2
600 20% 0.02 444 250 00 01

129
 Rigid drive
– The moment of inertia of the driven rotary masses (including propeller shaft) should
not exceed max. 0.01 kgm2.

Resilient drive
– If the moment of inertia is greater than 0.01 kgm2, a resilient coupling must be in-
stalled.
– Always mount the resilient coupling on the unit to be driven.
– Take length of resilient coupling into consideration when calculating length of pro-
peller shaft.
– Ensure that the engine speed does not drop below 1,200 rpm when the PTO is fully
loaded.
N26.45-0214-20
N26.45-0214-20

Resilient PTO coupling

130
 Dimensions of coupling flange – PTO at rear of engine (mm)
aØ bØ cØ d e fØ Number
of
holes

100 84±0.1 57h8 7 2 8.1±0.15 6

Dimensions of resilient coupling (mm)

Number Outer
N23.20-0202-20 of dia-
Clutch aØ bØ cØ e fØ holes meter Width
Flange
Reich 102 84±0.1 57h8 2 M8 6 212 83

N23.20-2001-22

131
 13.5 Installation of propeller shaft
When installing propeller shafts observe the following:
– Installation instructions from propeller shaft manufacturer.
– If necessary install several propeller shafts with intermediate bearings.
– The flanging surfaces must be completely flat.
– The angularity must be identical at both joints (β1 = β2). The angles must not be grea-
ter than 6° or less than 1°.
– Do not remove balancing plates.
– Ensure that markings on propeller shafts coincide when installing.
– Eliminate vibrations, if present, e.g. by selecting the best possible propeller shaft ang-
le.
N41.00-0224-20

β1 = β2

Types of angularity
Angularity in a single plane (two-dimensional angularity):
W or Z-type angularity
Angularity into two planes (three-dimensional angularity):
In the case of three-dimensional angularity, the driving and driven shafts intersect in
different planes (combined W and Z-type angularity).
The inner universal joint yokes must be offset to compensate for speed fluctuations

N41.00-0225-20
β1 = β2

132
Index Body/equipment manufacturer 10 Compressed air lines 30
Body/equipment manufacturer system 8 Compressors 128
Body/equipment mounting directives 6, 9 Connection, communication systems 34
A Bolted connections 24 Connections for brake system
Accident prevention 30 Box bodies 80 (semitrailer tractor) 112
Accident prevention regulations 13, 63 Box-type bodies 83 Connections for electrical system
Additional equipment, pneumatic 28 Brake system 39 (semitrailer tractor) 112
ADR 103 Braking characteristics 11, 18 Console mounting 78
Aggressive substances, transport 104 Build height, low frame b. 73 Consoles 76
Angular offset 45 Butt strap joint 80 Cooling 20
Anti-skid chains 19, 51 Corrosion protection measures 13
Anti-theft alarm system 62 Corrugated sheath 61
Articulated bearings 96 C Coupling heads (semitrailer tractor connection
Attachment height for semitrailer coupling 113 Cab 13, 55 lines) 112
Attachment plate for snow plough 104 Cable connector 57 Crane pillars, not centred 85
Attachments above cab 55 CAN bus 118 Cutting the frame 42
Automatic transmission 29 CAN language (protocol) 118
Auxiliary equipment 50 Cavities 13
Auxiliary equipment, pneumatic 28 CB radio 34 D
Auxiliary load 56 Cement silos 98 Detachable parts 50
Centre of gravity 11 Dimensions 16
Centre of gravity heights 18 Dimensions of coupling flange - PTO at
B Centre-axle trailer 65, 68 rear of engine 131
Belt drive 128 Channel dimensions 74 Disk brakes 40
Bending radii for plastic lines 40 Channel dimensions of dump truck bodies 97 Distance, at holes 37
Berufsgenossenschaft 13, 63 Channel height 74 Drawbar value 63
Bodies, torsionally rigid 80 Chassis frame 36 Drawings of products offered 8
Body equipment approval 6 Chassis frame, material 36 Drawings of the body 7
Body manufacturer 7, 11, 13 Chocks 50 Drilling holes in frame 37
Body manufacturer Information 9, 11 Clearance dimensions 64 Driving characteristics 18
Body mount spacing, dry bulk bodies 101 Clearance dimensions, trailer coupling 63 Dry bulk bodies 100
Body/equipment approval 6 Combustible substances, transport 103 Drying the paint 32
Composite materials 14 Dump truck bodies 96
Dump truck body mounting frame 97
Dump truck pump 126

133
E H M
Electrical system 33, 56 Handling 11 Main battery switch 33
Electrical wiring 61 hazardous goods, transport 103 Maintenance 27
Electrode diameter 38 High-Speed Controller Area Network Maintenance Booklet 10
Electromagnetic compatibility 35 (HS-CAN Bus) 118 Maintenance instructions 12
End cross member 47, 63 Hole diameter 37 Material cycles 14
Engine air intake 21 Hole interval 37 Material quality 71
Engine air, baffle 83 Hydraulic pump, installation 127 Materials 14
Engine, warning buzzer 35 Hydraulic pumps 128 MB body/equipment mounting directives 6
Equipment 12 Hydraulic tailgates 72, 106 MB-AS body/equipment manufacturer system 8
Exhaust system / silencers 27 MB-AS title page 9
Mercedes star 12
I Minimum front axle load 22
F IES 118 Mobile communication systems 34
Fax call-up system 6, 9 Installation of lighting 62 Modem, data call-up 9
Filling level 101 Installation of propeller shaft 132 Modifications to frame 46
Fire extinguishing pumps 128 Insulating sheath 61 Moments of resistance, rear-mounted
Fire fighting vehicles 105 Insurance carrier 13 loading cranes 94
Fire protection 103 Integrated electronic system 118 Mounting frame 70
Floor group, as mounting frame 75 Interchangeable bodies 83 Mounting frame moments of resistance of dump
Form-locking rigid connection - butt strap joint 80 ISDN, data call-up 9 truck bodies 97
Four-circuit protection valve 28 Mounting frame moments of resistance of special
Free space for assemblies 26 tilting bodies 99
Free space for cab 26 L Mounting frame moments of resistance, dry bulk
Friction-locking connection - console mounting 78 Labour protection 13 bodies 101
Leading axle 23 Mounting frame, design 72
Leaf springs 31 Mounting frame, securing 76
G Lifting axle 95 Mudwing (semitrailer tractor) 111
GGVS 103 Load indicator with warning device 101 Mudwings 51
Glass transport superstructures 72 Loading and unloading plans 101 Municipal vehicles 105
Loading crane, behind cab 85
Loading crane, rear-mounted 90
Loading cranes 72, 84 N
Loading cranes, heavy 80 Noise insulation 25
Longitudinal members, high 73
Longitudinal members, necessary fixation 76
Longitudinal members, sectional taper 72

134
O Q S
Offer drawings 9 Quality assurance 15 Safety and roadworthiness 10
Offset systems 77 Quick charge 33 Safety precautions for dump truck bodies 96
Operating Instructions 12 Quick charger 33 Safety regulations 103
Outriggers 90 Quick detaching lock for interchangeable Securing elements (consoles), as optional
Outriggers, loading crane 85, 90 bodies 81 equipment 76
Self-supporting bodies 82
Semitrailer 111
P R Semitrailer coupling 111
Paintwork 32 Radio equipment 34 Semitrailer coupling load, permissible 115
Parabolic springs 31 Recycling 14 Semitrailer tractor chassis 113
PC programme 9 Refuse collection trucks 105 Semitrailer tractor with standard chassis 116
Pin coupling, automatic 65 Reinforcements 36 Separate compartments 101
Planning 14 Removable loading crane 95 Side underride guards 54
Planning of bodies 16 Repair 27 Silencer 27
Plastic lines, bending radii 40 Reprocessing of components 14 Single hydraulic pump 128
Plastics 14 Resilient drive 130 Snow chains 19, 51
Platform bodies 83 Retarder 19 Spare wheel 51
Platform superstructures 71, 84 Rigid drive 130 Special equipment 25
Platform-mounted tanks 102 Roadworthiness 10 Special tilting bodies on standard chassis 98
Power supply auxiliary loads 56 Roll-off and removable dump truck bodies 105 Spoilers 55
Power take-offs 9, 122 Routing communication systems 34 Stabilizers 18
Power take-offs, available 122 Steerability 22
Power take-offs, maximum moment of inertia 125 Steering characteristics 11, 18
Product information brochures 8 Superstructures 70
Product liability 6, 10
Profile transition 73
Programmable special module 20, 118
Propeller shaft drive 128
Propeller shafts 44
PSM 20, 118
PTO at front of engine 128
PTO at rear of engine 129
PTO capacity, permissible 124
PTO, installation guidelines 124
Pump capacity (dump truck pump) 127

135
T Truck 2, 5
Tandem hydraulic pump 128 Truck-mounted cement mixer 104
Tank bodies 100 Tubular cross member 93
Tanks 80 Turning circle 41
Technical counseling 6 Twist lock 84
Technical wheelbases 17 Twisting, diagonal 10
Telephone 34 Types of angularity (propeller shaft) 132
Telescopic masts 72 Types of bodies 82
Test cables 33 Tyres 19
Test equipment, suitable 15
Tightening torques 24
Tilting angle, bodies on standard chassis 98 U
Tilting bodies 72 Underride guard 52
Tilting press 96
Tilting the cab 32
Total operating height 29 V
Towing and tow starting 32 Van bodies 83
Towing superstructures 72 Vehicle approval 16
Traction control 23 Vehicle modifications 16
Trademarks 12 Vehicle overhang 17
Trailer coupling 63
Trailer coupling for centre-axle trailers 68
Trailer drawbar load 65 W
Trailer loads 49, 65 Warning buzzer, engine 35
Trailing axle 23, 95 Warranty claims 11
Transmission-dependent PTOs 124 Weight distribution 17
Weights 16
Welded connections 25
Welding work 30
Wheelbase modifications 41
Wheelhouses 51
Wing (semitrailer tractor) 111
Wing 51
Winter road service vehicles 104
Wood strips 70

136
941 584 23 00 Order No. 6462 4003 02 Englische Ausgabe